AMS03-3

AEROSPACE
MATERIAL SPECIFICATION Issued 2015-04

Protection of Aluminum Alloys by Sprayed Metal Coatings

RATIONALE

This Standard is a direct replacement for DEF STAN 03-3 and has been reproduced by SAE International under the Open
Government Licensing Agreement. The technical content remains unchanged from Issue 5 of the Defence Standard it
supersedes. Any queries should be referred via the link shown in the feedback box at the bottom of this page.

LICENSING AGREEMENT

Ministry of Defence. Crown Copyright 2015. Reproduced under the terms of the Open Government License.

FOREWORD

REVISION NOTE

This Defence Standard was raised to Issue 5 to update its content and incorporate the latest MoD/DStan policy in place at
the time.

HISTORICAL RECORD

This standard supersedes the following:

Def Stan 03-3 / Issue 1 dated 28 December 1970

Def Stan 03-3 / Issue 2 dated 24 February 1995

Def Stan 03-3 / Issue 3 dated 24 May 2002

Def Stan 03-3 / Issue 4 dated 22 January 2008

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INTRODUCTION

In certain environments some high-strength aluminum alloys are more susceptible to surface corrosion, stress-corrosion or
exfoliation corrosion than pure aluminum. The application of an adherent coating of pure aluminum, pure zinc, or certain
alloys of these metals, will provide corrosion protection to the basis metal by exclusion of the corrosive environment and/or
by sacrificial corrosion of the coating metal. The particular coating to be used shall be defined on the relevant drawing or
contract but care must be taken in the choice of the most suitable coating for a particular alloy in a given set of conditions.

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TABLE OF CONTENTS

1. SCOPE .......................................................................................................................................................... 4

2. WARNING ..................................................................................................................................................... 4

3. NORMATIVE REFERENCES ....................................................................................................................... 4

4. DEFINITIONS ............................................................................................................................................... 4

5. INFORMATION TO BE SUPPLIED TO THE PROCESSOR ........................................................................ 5

6. PROCESS CONTROL .................................................................................................................................. 5

7. PROCESS REQUIREMENTS ...................................................................................................................... 5

7.1 General.......................................................................................................................................................... 5
7.2 Pre-Cleaning ................................................................................................................................................. 5
7.3 Abrasive Blasting .......................................................................................................................................... 6
7.4 Coating Materials .......................................................................................................................................... 6
7.4.1 Aluminum ...................................................................................................................................................... 6
7.4.2 Aluminum-Zinc .............................................................................................................................................. 7
7.4.3 Zinc................................................................................................................................................................ 7
7.5 Metal Spraying .............................................................................................................................................. 7
7.6 Supplementary Coatings ............................................................................................................................... 8

8. INSPECTION AND TEST ............................................................................................................................. 8

8.1 Appearance ................................................................................................................................................... 8
8.2 Thickness ...................................................................................................................................................... 8
8.3 Adhesion ....................................................................................................................................................... 8
8.4 Composition .................................................................................................................................................. 8
8.5 Porosity ......................................................................................................................................................... 8

9. RECTIFICATION OF DEFECTIVE COATINGS ........................................................................................... 8

10. NOTES .......................................................................................................................................................... 8

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1. SCOPE

This SAE Standard specifies the requirements for the application of sprayed metal coatings of aluminum, zinc, or aluminum-
zinc based alloys for the protection of aluminum alloys against corrosion. It does not cover the metal spraying of aluminum
armour materials, which should be treated in accordance with the requirements of Def Stan 08-39.

2. WARNING

This section which appeared in DEF STAN 03-3 Issue 5 has been deliberately deleted.

3. NORMATIVE REFERENCES

3.1 The publications shown below are referred to in the text of this standard. Publications are grouped and listed in alpha-
numeric order.

BS EN ISO 2063 Thermal Spraying. Metallic and Other Inorganic Coatings. Zinc, Aluminium and their Alloys

BS EN ISO 3882 Metallic and Other Inorganic Coatings. Review of Methods of Measurement of Thickness

BS EN 573-3 Aluminium and Aluminium Alloys. Chemical Composition and Form of Wrought Products. Chemical
Composition and Form of Products.

BS EN 1179 Zinc and Zinc Alloys. Primary Zinc

BS EN ISO 11126-7 Preparation of Steel Substrates before Application of Paints and Related Products. Specification
for Non-Metallic Blast Cleaning Abrasives. Part 7F: Fused Aluminium Oxide

Def Stan 03-2 Cleaning and Preparation of Metal Surfaces

AMS03-2 Cleaning and Preparation of Metal Surfaces

Def Stan 08-39 Cutting, Welding and Corrosion Protection of Aluminium Alloy Military Equipment.

3.2 This section which appeared in DEF STAN 03-3 Issue 5 has been deliberately deleted.

3.3 This section which appeared in DEF STAN 03-3 Issue 5 has been deliberately deleted.

3.4 This section which appeared in DEF STAN 03-3 Issue 5 has been deliberately deleted.

4. DEFINITIONS

4.1 For the purposes of this part of the Standard, the following definitions apply:

4.2 PROCESS CONTROL SCHEDULE

The document which specifies/defines:

a. The sequence of manufacturing operations and processes.

b. The control parameters and their tolerances for each individual process within the total sequence.

4.3 SIGNIFICANT SURFACE

The area of the item, covered or to be covered by the coating, and for which the coating is essential for serviceability and/or
appearance.

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5. INFORMATION TO BE SUPPLIED TO THE PROCESSOR

The following information shall be given on the drawing, contract or order:

a. The number of this AMS Material Specification or its superseded Defence Standard.

b. The specification and metallurgical condition of the basis metal.

c. The significant surface. This may be indicated on the drawing or by a marked sample.

d. The details of the abrasive blasting process and surface roughness to be achieved.

e. The coating process to be used.

f. The details of any pre and post-deposition heat treatment.

g. The thickness of the coating required and details of any other test criteria.

h. The details and thickness of any necessary undercoat to be applied.

i. The details of any finishing treatment required.

j. The details of any special requirements (e.g., masking).

6. PROCESS CONTROL

6.1 A Process Control Schedule suitable of achieving the requirements of this Standard shall be prepared by the
processing contractor(s) prior to the commencement of production.

6.2 Details of the coating process, including all preparatory treatments and post coating treatments, processing, thickness
of coating, significant surfaces, tests and all other processes and treatments shall be included in the Process Control
Schedule.

6.3 All stages in the complete Schedule shall follow each other without delay.

7. PROCESS REQUIREMENTS

7.1 General

7.1.1 The protection afforded by any given coating depends to a large extent on its adhesion to the basis metal. The
degree of adhesion depends on the thoroughness of preparation of the basis metal, the avoidance of delay in the
subsequent application of the specified coating and the spraying technique.

7.1.2 The composition and structure of the deposit determines the general corrosion rate and hence the life of the coating.
They are closely dependent on the metal spray process and the parameters employed. Therefore, the process and
parameters must be defined and referenced in the Process Control Schedule and carefully controlled during spray
deposition.

NOTE: There can be large differences in composition between the coating and the feedstock if one of the elements of the
feedstock has a high vapor pressure, leading to preferential elemental loss (e.g., zinc).

7.2 Pre-Cleaning

All surfaces shall be free from solids such as soap, drawing compounds, oil, grease, machine fluid, polishing compounds,
etc., discoloration or other foreign matter. All items shall be degreased prior to the commencement of a cleaning sequence,
which shall be in accordance with AMS03-2/Def Stan 03-2, to produce a chemically clean surface. Drying by means of
chlorinated solvents shall not be permitted.

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7.3 Abrasive Blasting

7.3.1 Immediately following pre-cleaning (see 7.2) the surface shall be roughened, to provide an adequate key, by
blasting with Aluminum Oxide Grit (e.g., BS EN ISO 11126-7 N/FA-A/G 0.5-1). The abraded surface shall present
an even matt appearance.

NOTE: The alumina shall not have been used on any other type of material (e.g., steel, copper rich alloys or otherwise
externally contaminated).

7.3.2 Care shall be taken to avoid using abrasives which are insufficiently coarse or which have lost angularity with use
in re-circulating blast cabinets. The coarseness and angularity of the abrasive used have a great effect on the
adhesion of the coating. Direct pressure blasting methods shall be used (with a maximum pressure limitation of 3.5
bar to avoid excessive breakdown of alumina) except in the case of thin sections.

NOTE: Direct pressure blasting is preferable to suction blasting because of the slowness and poor roughening
characteristics of the latter.

7.3.3 Immediately following the abrasive blasting, residual grit shall be removed from the metal surface by a jet of clean,
dry air which shall be free from oil and dust.

7.3.4 Items which have been abraded shall be handled with clean rubber, cotton or smooth plastic gloves only. All
contamination with dust, dirt, oil, grease, and water shall be avoided.

7.3.5 Operations may sometimes have to be carried out on local areas only. In such cases suitable masking will be
necessary. For abrasive blasting, the masking shall consist of metal shields, plugs, cloth or strong paper tapes, or
any other suitable material which affords protection from the abrasive blasting. Care should be taken in the choice
of masking materials for local areas, so that the removal of masks is not impeded by over-spray.

7.3.6 The abraded surface will be in a very active state and any deterioration will very readily affect the performance of
the sprayed metal coating. Metal spraying, therefore, shall be applied as soon as possible after abrasive blasting
and before visible deterioration of the surface has occurred. Under good workshop conditions an interval of 4 hours
shall not be exceeded and under on-site conditions spraying shall follow abrasive blasting within a few minutes. In
the event of contamination, the surface shall be re-prepared as necessary.

7.4 Coating Materials

The metals used for coating shall conform to the compositional requirements detailed below. Additionally every precaution
must be taken to prevent their contamination prior to and during processing. In particular the re-use of metal powders is
prohibited. The coating metal to be applied shall be in the form of wire or powder appropriate to the particular spraying
apparatus employed and shall normally be chosen from the following grades:

7.4.1 Aluminum

7.4.1.1 Grade ALG

The chemical composition of the coating metal shall be in accordance with the requirements of BS EN 573-3, EN AW 1050A
(99.5% aluminum).

7.4.1.2 Grade ALS

This grade is suitable for more severe service conditions than grade ALG (e.g., for the protection of high-strength alloys
against stress-corrosion when stressed in the short transverse direction). The chemical composition of the coating metal
shall be in accordance with the requirements of BS EN 573-3, EN AW 1080A, but the copper impurity level shall be limited
to 0.01% max.

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7.4.2 Aluminum-Zinc

7.4.2.1 Grade AZG

The coating metal shall be manufactured from:

Zinc (BS EN 1179, Grade Z3) 1.0 to 4.5%

Aluminum (to BS EN 573-3, EN AW 1050A) remainder

7.4.2.2 Grade AZS

This grade is suitable for more severe service conditions than grade AZG and shall be manufactured from:

Zinc (BS EN 1179, Grade Z3) 1.0 to 4.5%

Copper content shall not exceed 0.01% in final wire

Aluminum (to BS EN 573-3, EN AW 1080A) remainder

7.4.2.3 Grade AZSP

This grade is particularly suitable for the protection of 7000 series aluminum alloys against stress corrosion cracking at weld
toes under severe service conditions. The composition of the feedstock is based on super pure (SP) aluminum containing
small percentages of activator elements such as indium and tin. The avoidance of copper and iron is crucial. The coating
metal shall be manufactured from:

Zinc (BS EN 1179, Grade Z3) 0.6 to 1.0%

Tin 0.08 to 0.1%

Indium 0.17 to 0.19%

Aluminum (Super pure 99.99%) remainder

All other elements Max 0.001%

7.4.3 Zinc

7.4.3.1 Grade Z3

The chemical composition of the coating metal shall be in accordance with the requirements of BS EN 1179, Grade Z3
(99.95% Zn).

7.5 Metal Spraying

7.5.1 The coating shall be applied by wire or powder spraying, in a manner that effectively avoids undue oxidation of the
coating metal.

7.5.2 Thin sections shall be coated by several light passes so that distortion and overheating are avoided.

7.5.3 Overheating of heat-treatable aluminum alloys shall be avoided lest they suffer loss of mechanical properties. The
sprayed work must not be allowed to reach a temperature in excess of 60 C and the Process Control Schedule
shall define how this is to be controlled (e.g., thermal crayons, etc.).

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7.6 Supplementary Coatings

7.6.1 Contamination of the absorbent newly sprayed metal by oil, grease, moisture, dirt, finger marks, etc., shall be
avoided, consequently the addition of any specified supplementary coating, such as paint, shall be carried out
without significant delay after the metal sprayed coating has been satisfactorily completed.

7.6.2 The possible loss of sacrificial properties of the coating, caused by the application of a supplementary coating, such
as paint, should be considered.

8. INSPECTION AND TEST

The sprayed coatings shall meet the following requirements.

8.1 Appearance

The coating shall be clean, matt, of uniform texture and free from lumps and spatter.

8.2 Thickness

The average thickness of the sprayed metal shall be between 100 and 200 m. The minimum local thickness shall be not
less than 75 m. The method (selected from BS EN ISO 3882) and frequency of thickness determination shall be specified
in the Process Control Schedule.

8.3 Adhesion

The method (see BS EN ISO 2063 Annex A) and frequency of testing the adhesion of the deposit shall be specified in the
Process Control Schedule.

8.4 Composition

The method and frequency of testing the composition of the deposit shall be specified in the Process Control Schedule.

8.5 Porosity

The method and frequency of testing the porosity of the deposit shall be specified in the Process Control Schedule.

9. RECTIFICATION OF DEFECTIVE COATINGS

9.1 Areas rejected under 8.1 shall be suitably pre-treated and re-sprayed where necessary in accordance with the
requirements of Section 7.

9.2 Areas rejected under 8.2 shall be cleaned by light abrasive blasting and re-sprayed in accordance with 7.5 to achieve
the specified coating thickness.

9.3 Items or areas rejected under 8.3, 8.4, and 8.5 may, after removal of the defective coating, be re-sprayed in
accordance with the requirements of Section 6, as detailed in the Process Control Schedule.

10. NOTES

10.1 A change bar (l) 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.

UNDER THE JURISDICTION OF AMS COMMITTEE "B"

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