AMS 3266 Electrically Conductive Sealant PDF

AMS3266™ REV.
A
AEROSPACE
MATERIAL SPECIFICATION Issued 1989-10
Revised 2017-02
Superseding AMS3266
Sealing Compound, Polythioether Elastomeric

Two-Part Electrically Conductive
RATIONALE
Specification review and update to incorporate current customer requirements and product performance capabilities. Adds
types for chromated and non-chromated sealants, and updates electrical properties and shelf life requirements to match
product performance. Changed standard and accelerated curing times to provide more consistent testing.
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1. SCOPE
1.1 Form
This specification covers two types of electrically conductive, elastomeric polythioether sealing compounds that cure at
room temperature. The sealing compound is supplied as either a two-component system or as premixed and frozen.
1.2 Application
These materials primarily provide an electrically conductive sealant or metal joint interface for shielding purposes. They
have been used in aircraft to provide an electrically conductive path in faying surface seals as well as overcoating of
fasteners and sealing of seams and joints along with providing an effective corrosion barrier. They have a continuous
service use from -65 to +250°F (-54 to +121°C). The cured sealant materials are resistant to exposure to both jet fuel and
aviation gas.
1.3 Classification
1.3.1 Types
Type 1 - Contains chromate type corrosion inhibitors.

Type 2 - Contains non-chromate type corrosion inhibitors.
1.3.2 Classes
Class B - Suitable for application by extrusion gun or spatula. Available with the following application times in hours:
B-1
B-2
1.4 Safety - Hazardous Materials
Shall be in accordance with AS5502 (1.1).
__________________________________________________________________________________________________________________________________________
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SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and
suggestions.
Copyright © 2017 SAE International
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recording, or otherwise, without the prior written permission of SAE.
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Copyright SAE International Order Number: W2001964
Provided by IHS under license with SAE Email: [email protected] Sold to:RSG AERODESIGN [156883100001] - [email protected],
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SAE INTERNATIONAL AMS3266™A Page 2 of 12
2. APPLICABLE DOCUMENTS
The issue of the following documents in effect on the date of the purchase order forms a part of this specification to the
extent specified herein. The supplier may work to a subsequent revision of a document unless a specific document issue
is specified. When the referenced document has been cancelled and no superseding document has been specified, the
last published issue of that document shall apply.
2.1 SAE Publications
Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA
and Canada) or +1 724-776-4970 (outside USA), www.sae.org.
AMS2629 Fluid, Jet Reference
AMS-S-8802 Sealing Compound, Fuel Resistant, Integral Fuel Tanks and Fuel Cell Cavities
AS5127 Aerospace Standard Test Methods for Aerospace Sealants Methods for Preparing Aerospace Sealant
Test Specimens
AS5127/1 Aerospace Standard Test Methods for Aerospace Sealants, Two-Component Synthetic Rubber
Compounds
AS5502 Standard Requirements for Aerospace Sealants and Adhesion Promoters
2.2 U.S. Government Publications
Copies of these documents are available online at http://quicksearch.dla.mil.
MIL-PRF-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base, NATO Code Number O-156
MIL-PRF-83282 Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon Base, Metric, NATO Code Number H-537
2.3 NAS Publications
Available from Aerospace Industries Association, 1000 Wilson Boulevard, Suite 1700, Arlington, VA 22209-3928, Tel: 703-
358-1000, http://www.aia-aerospace.org/
NAS705 Terminal, Stud-Turret, Single End, Midget
2.4 ASTM Publication
Available from ASTM International, 100 Barr Harbor Drive, P.O. C700, West Conshohocken, PA 19428-2959, Tel. 610-
832-9585, www.astm.org
ASTM B117 Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM B221 Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
2.5 PRI Publications
Available from Performance Review Institute, 161 Thorn Hill Road, Warrendale, PA 15086-7527, Tel: 724-772-1616,
www.pri-network.org.
PD2103 Aerospace Quality Assurance, Product Standards, Qualification Procedure, Sealants
PRI-QPL-AMS3266 Products Qualified Under AMS3266
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Provided by IHS under license with SAE Sold to:RSG AERODESIGN [156883100001] - [email protected],
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3. TECHNICAL REQUIREMENTS
3.1 Materials
The basic ingredient shall be synthetic rubber, made from polythioether polymer, and shall contain nickel filler and
corrosion inhibitors suitable to the designated Type. The sealing compound shall cure by the addition of a separate curing
agent to the base compound and shall not depend on solvent evaporation for curing. The curing agent shall contain either
manganese dioxide curative or epoxy curative, and possess sufficient color contrast to the base compound to permit easy
identification of an unmixed or incompletely mixed sealing compound. Neither the base compound nor the cured sealing
compound shall be red or pink in color.
3.1.1 Adhesion Promoter
The Adhesion Promoter shall be an air drying liquid and shall be included as part of the package with the base compound.
3.2 Date of Packaging
3.3 Toxicological Formulations
3.4 Quality
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3.5 Shelf Life
Shelf life shall be a minimum of 6 months from the date of packaging when stored at 40 °F to 60 °F (4 °C to 16 °C) in the
original unopened containers, with intermittent temperature excursions allowed during shipment. The manufacturer may
recommend storage at lower temperatures to preserve application and handling properties. Material may be retested for
shelf life extension per 4.3.3.
3.5.1 Premixed and Frozen Material
Premixed and frozen material shall have a minimum storage life of 30 days at -80 °F (-62 °C) or lower from date of
mix/freeze. The date of mix/freeze shall be within the shelf life of the unmixed material.
3.6 Properties
The base compound and the curing agent, when mixed in accordance with manufacturer’s instructions and cured in
accordance with 4.5.3.5, shall conform to the requirements shown in Table 1, when determined in accordance with the
specified test methods.

Table 1 - Properties
Test Procedures
Paragraph Property Requirement (Paragraph)
3.6.1 Nonvolatile Content, 92% AS5127/1 (5.1)

by weight, min
3.6.2 Application Time, min AS5127/1 (5.6)

From beginning of mixing, AS5127/1 (5.6.2)
not less than 15 g/min
shall be extruded.
B-1 1 hour
B-2 2 hours
3.6.3 Tack-Free Time (Measured from beginning of AS5127/1 (5.8)

mixing), max
B-1 10 hours
B-2 24 hours
3.6.4 Standard Cure Time (time to reach 30 AS5127/1 (5.9)

Durometer A), max
B-1 72 hours
B-2 72 hours
3.6.5 Specific Gravity 1.9 – 2.25 AS5127/1 (6.1)
3.6.6 14 Day Hardness, Durometer Shore A, 40 AS5127/1 (6.2)

Instantaneous, min
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3.6.7 Hydrolytic Stability, min 40 Shore A AS5127/1 (6.6)
3.6.8 Thermal Stability, 48 hours at 250 °F (121 °C) No blistering or sponging; AMS3266 (4.6.3)
hardness shall not deviate more
than ±15 from initial
3.6.9 Low Temperature Flexibility No visual evidence of cracking, AMS3266 (4.6.2) and
checking or loss of adhesion AS5127/1 (7.6)
3.6.10 Electrical Contact Resistance AMS3266 (4.6.1)

3.6.10.1 Initial, max, Type 1 0.05 Ω
Initial, max, Type 2 0.5 Ω
3.6.10.2 After 1000 hours Salt Spray, max 1.0 Ω
3.6.11 Tensile Strength and Elongation, min AS5127/1 (7.7)
3.6.11.1 Standard Cure 50 psi (345 kPa)/40%
3.6.11.2 Standard cure plus 48 hours at 140 °F (60 °C) 50 psi (345 kPa)/40%
in AMS2629, Type 1
in MIL-PRF-23699

Table 1 – Properties (Continued)
Test Procedures
Paragraph Property Requirement (Paragraph)
3.6.11.4 Standard cure plus 24 hours at 250 °F 50 psi (345 kPa)/40%

(121 °C) in MIL-PRF-23699
in MIL-PRF-83282
3.6.12 Shear Strength, min 40 psi (276 kPa), AS5127/1 (7.8)

95% cohesive failure
3.6.13 Corrosion Resistance

3.6.13.1 Type 1 No pitting corrosion under AMS3266 (4.6.4)
conductive sealant
3.6.13.2 Type 2 No corrosion or signs of AS5127/1 (7.9)

deterioration under the sealant
3.6.14 Storage Stability
3.6.14.1 Accelerated Storage AS5127/1 (9.1)

Storage time shall be 7 days at
120 °F (49 °C)
3.6.14.1.1 Appearance No skinning, hardening or

separation that cannot be
restored by normal agitation
3.6.14.1.2 Application Time, min AS5127/1 (5.6)

From beginning of mixing, AS5127/1 (5.6.2)
not less than 5 g/min shall be extruded.
B-1
B-2 1 hour
2 hours
3.6.14.1.3 Tack Free Time Same as 3.6.3
3.6.14.1.4 Standard Cure Time Same as 3.6.4
3.6.14.2 Long Term Storage AMS3266 (4.6.5)
3.6.14.2.1 Appearance No skinning, hardening or

separation that cannot be
restored by normal agitation
3.6.14.2.2 Application Time Same as 3.6.14.1
3.6.14.2.3 Tack-Free Time Same as 3.6.3
3.6.14.2.4 Standard Cure Time Same as 3.6.4
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4. QUALITY ASSURANCE PROVISIONS
4.1 Responsibility for Inspection
4.1.1 Source Inspection
Shall be in accordance with AS5502 (4.1.1).
4.1.2 Sampling and Testing
4.2 Classification of Tests
4.2.1 Qualification Tests
4.2.1.1 Qualification Requirements for Class B-2
Class B-2, if available, shall be the first material that is qualified for each supplier of sealing compound. Class B-2 sealing
compound shall be tested for, and shall meet all technical requirements of this specification with the exception of
requirements unique to other application times or Types of the sealing compound.
4.2.1.2 Qualification Requirements for Other Application Times
Once qualification for Class B-2 has been obtained (or B-1 if no B-2 exists), other application times of qualified classes
may be qualified. The formulation for other application times of qualified classes shall be the same as Class B-2 except for
minor variations necessary for conformance to application time requirements. All compounds shall meet all technical
requirements of this specification. Application times of qualified classes need only to be tested to the initial acceptance
tests listed in 4.2.2 and other tests as defined by the QPL agency. Any unique qualification tests for the sealant’s
application time shall also be tested per PD2103.
4.2.2 Initial Acceptance Tests
Requirements shown in Table 2 are initial acceptance tests and shall be performed on each batch in accordance with
AS5502 (4.2.2.1).
Table 2 - Initial acceptance tests
Test Requirement Paragraph

Application Time 3.6.2
Tack-Free Time 3.6.3
Standard Cure Time 3.6.4
Electrical Contact Resistance, Initial only1 3.6.10.1
NOTE 1: For acceptance tests, sealant may be subjected to an accelerated cure
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per 4.5.3.5.
4.2.3 Final Acceptance Tests
Requirements shown in Table 3 are final acceptance tests and shall be performed on each lot in accordance with AS5502
(4.2.2.2).

Table 3 - Final Acceptance Tests

Application Time 3.6.2
4.3 Sampling and Testing
4.3.1 Qualification Tests
Samples shall be produced using production scaled equipment. Enough material shall be supplied to perform all required
tests. Samples shall be identified as specified herein and below:
SEALING COMPOUND, POLYTHIOETHER ELASTOMERIC TWO-PART ELECTRICALLY CONDUCTIVE

AMS3266A TYPE AND CLASS
MANUFACTURER’S IDENTIFICATION _________________________________________________________________
BATCH/LOT NUMBER_______________________________________________________________________________
DATE OF PACKAGING ______________________________________________________________________________
SHELF LIFE EXPIRATION DATE ______________________________________________________________________
STORE BEETWEEN 40 °F (4 °C) AND 60 °F (16 °C)
4.3.2 Acceptance Tests
4.3.2.1 Batch and Lot
A batch shall be defined as the quantity of material run through a mill or mixer at one time. A lot shall be defined as
material from one batch of each component assembled (packaged) as finished product in one size and/or type of
container at the same time. The lot, when used, shall be traceable to the batches of base compound and curing agent.
4.3.2.2 Initial and Final Acceptance Tests
Each batch shall be subjected to both initial and final acceptance testing. Initial acceptance tests are those listed in
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Table 2. After successful completion of the initial acceptance tests, the batch shall be released for final packaging. During
packaging, test kits shall be selected at random for final acceptance testing. Final acceptance testing is to be conducted
on the final packaged product and consist of those tests outlined in Table 3.
4.3.2.3 Final Acceptance Tests for Different Types and/or Size Containers
If the batch is being packaged in different types and/or size containers, the final acceptance tests shall be conducted on
each type and/or each size containers. If the sealing compound is being procured under different purchase orders, but the
purchase orders call for the same type and size containers, it is only necessary to conduct the final acceptance tests one
time.
4.3.3 Shelf Life Extension
4.3.3.1 Shelf-Life Testing
The tests to be conducted for shelf-life extensions are listed in Table 4.

Table 4 - Shelf-life testing

Application Time 3.6.14.1
Electrical Contact Resistance, Initial only1 3.6.10.1
NOTE 1: For shelf life testing, sealant may be subjected to an accelerated cure
per 4.5.3.5.
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4.3.3.2 Time and Limits of Shelf Life Extensions
If the tests are performed at the end of the stated shelf life to update the shelf life of the sealing compound and all tests are
passed, then the shelf life may be extended an additional 3 months for kitted sealant in the original unopened containers,
or an additional 30 days for pre-mixed and frozen sealant.
4.4 Approval
4.5 Test Methods
4.5.1 Standard Tolerances
Unless otherwise specified herein, standard tolerances of AS5127 (Section 3) “Standard Tolerances” shall apply.
4.5.2 Standard Conditions
Standard laboratory conditions shall be as specified in AS5127 (Section 4).
4.5.3 Preparation of Test Specimens
4.5.3.1 Cleaning and Surface Preparation of Test Panels
Panels shall be prepared, cleaned, surface treated, and coated in accordance with AS5127 (Section 6) prior to application
of sealant for testing.
4.5.3.2 Preparation of Sealing Compound
Sealing compound shall be prepared in accordance with AS5127/1 (Section 4) “Preparation of Sealing Compound” and
subparagraphs (4.1) “Qualification Testing”, (4.2) “Acceptance Testing”, and (4.3) “Thawing of Quick-Frozen Sealing
Compound” as applicable.
4.5.3.3 Application of Adhesion Promoter
When adhesion promoter is used, it shall be applied in accordance with AS5127 (6.9) “Application of Adhesion Promoter.”
If adhesion promoter is used for qualification and initial or final acceptance testing, the adhesion promoter product shall be
reported.
4.5.3.4 Application of Sealing Compound
Unless otherwise specified herein, freshly mixed sealing compound shall be applied to test panels in accordance with
AS5127 (6.10) “Application of Sealing Compound”.

4.5.3.5 Curing of Sealing Compounds
Shall be in accordance with AS5127 (6.11) “Curing of Sealing Compounds.” For Qualification testing, Class B sealing
compounds shall be cured for 14 days at Standard Conditions. For Acceptance testing, Class B sealing compounds may
be given an accelerated cure for 48 hours at Standard Conditions followed by 24 hours at 140 °F (60 °C).
4.6 Test Procedures
Standard Test Methods are in accordance with AS5127 and AS5127/1. In the event of a conflict between the text of this
document and AS5127 and/or AS5127/1, the text of this document takes precedence.
4.6.1 Test Procedures for Electrical Contact Resistance
4.6.1.1 Test Specimen Preparation
At least ten test specimens shall be prepared as shown in Figure 1. Drill two holes using a No. 43 drill on one side on each
of the conversion coating (AS5127, 6.2) treated ASTM B221 aluminum angles, approximately 0.50 inch (12.7 mm) apart.
Press fit silver plated terminals, conforming to NAS705, into the drill holes. Swage the terminals to ensure the terminals
are held tightly into the aluminum angle. Solvent clean the faying surfaces of the angles per AS5127 (Section 6). Mix AMS-
S-8802, Class B-2, polysulfide sealant according to manufacturer's instructions. Apply mixed AMS-S-8802 sealant to both
faying surfaces. Place a piece of cotton duck cloth, 1.0 x 1.5 inches (25 x 38 mm), over the coated surface and impregnate
with sealant. Mate the two angles together and clamp. Also seal the terminal/angle joints with the same material. Allow to
cure for 24 hours at Standard Conditions. Remove the conversion coating from surface "A", as shown in Figure 1, with a
nylon scouring pad, or equivalent, and clean per AS5127 (Section 6). Apply a fillet of electrically conductive sealant to
surface "A". Assembly shall be left undisturbed while curing per 4.5.3.5 or for 48 hours at Standard Conditions followed by
24 hours at 140 °F (60 °C).
4.6.1.2 Resistance Measurements
A Four-Terminal probe with Kelvin connections (Keithley micro-ohmmeter model 580, model 2750, or equivalent) shall be
used to measure contact resistance. A 100-mA current shall be applied across the test assembly. The voltage drop shall
be measured and resistance can be calculated using the following formula:
Electrical Contact Resistance (Ω) = Voltage drop

0.1
4.6.1.3 Salt Fog Aging
Not less than five test specimens shall be prepared in accordance with 4.6.1.1 and subjected to a salt fog test for 1000
hours in accordance with ASTM B117. After salt fog conditioning, specimens shall be rinsed with water to removed any
salt deposits, and the specimens shall then be dried at Standard Conditions for 24 hours, followed by 24 hours at 140 °F
(60 °C) in an air-circulating oven. After cooling to Standard Conditions, contact resistance shall be measured and shall
meet the requirement of 3.6.10.2.
4.6.2 Low Temperature Flexibility
Low temperature flexibility shall be conducted in accordance with AS5127/1 (7.6). At the end of the Standard Cure in
accordance with 4.5.3.5, all four panels shall be immediately placed in a low temperature flexibility fixture and equilibrated
and tested at a temperature of -65 °F (-54 °C).
4.6.3 Thermal Stability
Sealant specimens, 1.0 x 2.0 x 0.075 inches (25 x 51 x 1.9 mm) and cured per 4.5.3.5, shall be conditioned in an air-
circulating oven for 48 hours at 250 °F (121 °C). After conditioning, the specimens shall be cooled to Standard Conditions
and tested for conformance to 3.6.8.
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4.6.4 Corrosion Resistance
Test specimens used for Salt Fog Aging (4.6.1.3) shall be disassembled by carefully removing the fillet of conductive
sealant to expose the surface of the substrate. The surface under the conductive sealant shall be visually examined under
10x magnification for conformance to 3.6.13.
4.6.5 Long Term Storage
Long Term Storage shall be conducted in accordance with AS5127/1 (9.2). The period of storage shall be 6 months, and
the temperature of storage shall be within 40 to 60 °F (4 to 16 °C).
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Figure 1 – Contact resistance test fixture configuration

4.7 Reports
4.8 Resampling and Retesting
4.9 Qualification
Shall be in accordance with AS5502 (4.7). All products with their corresponding adhesion promoter sold to this
specification shall be listed, or approved for listing, on the Qualified Products List, PRI-QPL-AMS3266. The qualified
products list shall be in accordance with PD2103.
5. PREPARATION FOR DELIVERY
Shall be in accordance with AS5502 (Section 5).

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6. ACKNOWLEDGMENT
7. REJECTIONS
8. NOTES
8.1 Revision Indicator
A change bar (|) located in the left margin is for the convenience of the user in locating areas where technical revisions, not
editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title
indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original
publications, nor in documents that contain editorial changes only.
8.2 Properties are divided into two classes: performance and application requirements. Performance requirements
define those properties of the cured sealant and its performance in service. Application requirements define those
properties of the uncured sealant and affect the application parameters of the sealant. Testing of both performance
and application properties are required during preproduction and prior to qualification. A subset of the performance
and application properties testing is required for acceptance testing. Minor variations in application requirements
during acceptance testing may not be cause for rejection if approved by the procuring agency.
8.3 The use of adhesion promoter is recommended for various substrates to achieve consistent results and obtain
optimum adhesion. The adhesion promoter should be used as directed by the manufacturer.
8.4 Recommended MIL-PRF-23699 and MIL-PRF-83282 fluids are Royco 500 and Royco 782, respectively.
8.5 Sealing compounds meeting the requirements of this specification have been classified under Federal Supply
Classification (FSC) 8030.
8.6 Dimensions and properties in inch/pound units and the Fahrenheit temperatures are primary; dimensions and
properties in SI units and the Celsius temperatures are shown as the approximate equivalents of the primary units
and are presented only for information.

8.7 Purchase documents should specify not less than the following:
AMS3266A
Type and class of sealing compound desired
Type and size of containers (kits) desired
Quantity of containers
Special packaging, if required.
PREPARED BY AMS COMMITTEE "G-9"
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AMS3266™ REV.

Sealing Compound, Polythioether Elastomeric

Type 1 - Contains chromate type corrosion inhibitors.

1.4 Safety - Hazardous Materials

Shall be in accordance with AS5502 (1.1).

2.1 SAE Publications

AMS2629 Fluid, Jet Reference

AS5502 Standard Requirements for Aerospace Sealants and Adhesion Promoters

2.2 U.S. Government Publications

Copies of these documents are available online at http://quicksearch.dla.mil.

2.3 NAS Publications

NAS705 Terminal, Stud-Turret, Single End, Midget

2.4 ASTM Publication

2.5 PRI Publications

PD2103 Aerospace Quality Assurance, Product Standards, Qualification Procedure, Sealants

PRI-QPL-AMS3266 Products Qualified Under AMS3266

Copyright SAE International Order Number: W2001964

3.1.1 Adhesion Promoter

3.2 Date of Packaging

Shall be in accordance with AS5502 (3.1).

3.3 Toxicological Formulations

Shall be in accordance with AS5502 (3.2).

Shall be in accordance with AS5502 (3.3).

3.5.1 Premixed and Frozen Material

Copyright SAE International Order Number: W2001964

3.6.1 Nonvolatile Content, 92% AS5127/1 (5.1)

3.6.2 Application Time, min AS5127/1 (5.6)

3.6.3 Tack-Free Time (Measured from beginning of AS5127/1 (5.8)

3.6.4 Standard Cure Time (time to reach 30 AS5127/1 (5.9)

3.6.5 Specific Gravity 1.9 – 2.25 AS5127/1 (6.1)

3.6.6 14 Day Hardness, Durometer Shore A, 40 AS5127/1 (6.2)

3.6.10 Electrical Contact Resistance AMS3266 (4.6.1)

3.6.11 Tensile Strength and Elongation, min AS5127/1 (7.7)

3.6.11.1 Standard Cure 50 psi (345 kPa)/40%

Copyright SAE International Order Number: W2001964

Table 1 – Properties (Continued)

3.6.11.4 Standard cure plus 24 hours at 250 °F 50 psi (345 kPa)/40%

3.6.12 Shear Strength, min 40 psi (276 kPa), AS5127/1 (7.8)

3.6.13 Corrosion Resistance

3.6.13.2 Type 2 No corrosion or signs of AS5127/1 (7.9)

3.6.14 Storage Stability

3.6.14.1 Accelerated Storage AS5127/1 (9.1)

3.6.14.1.1 Appearance No skinning, hardening or

3.6.14.1.2 Application Time, min AS5127/1 (5.6)

3.6.14.1.3 Tack Free Time Same as 3.6.3

3.6.14.1.4 Standard Cure Time Same as 3.6.4

3.6.14.2 Long Term Storage AMS3266 (4.6.5)

3.6.14.2.1 Appearance No skinning, hardening or

3.6.14.2.2 Application Time Same as 3.6.14.1

3.6.14.2.3 Tack-Free Time Same as 3.6.3

3.6.14.2.4 Standard Cure Time Same as 3.6.4

Copyright SAE International Order Number: W2001964

4. QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection

Shall be in accordance with AS5502 (4.1).

4.1.1 Source Inspection

Shall be in accordance with AS5502 (4.1.1).

4.1.2 Sampling and Testing

Shall be in accordance with AS5502 (4.3).