AIRBUS ®

AIPS05-05-004
Issue 4
Page 1 of 8
April 2010

AIPS
Airbus Process Specification

Wet installation of fasteners

Published and distributed by :

AIRBUS S.A.S.
ENGINEERING DIRECTORATE
31707 BLAGNAC Cedex
FRANCE

Copyright reserved
Ref. no. AIPS05-05-004

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Contents

1 Scope

2 Normative references

3 Definition, applicability and limitations

4 Requirements

5 Process qualification

6 Appendix

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1 Scope
This Airbus Process Specification defines the requirement for Wet installation of fasteners.
The purpose of this specification is to give design and quality requirements to manufacturers. Although the
essential requirements of a process are defined, the specification does not give complete in house process
instructions, these shall be given in the manufacturers detailed process instruction and supporting work
instructions.

This specification shall not be used as an inspection document unless parts or assemblies have been
manufactured according to this specification.

It shall be applied when mentioned in the relevant standard, material specification or drawing.

2 Normative references
This Airbus specification incorporates by dated or undated reference provisions from other publications. All
normative references cited at the appropriate places in the text are listed hereafter. For dated references,
subsequent amendments to or revisions of any of these publications apply to this Airbus specification only when
incorporated in it by amendment of revision. For undated references, the latest issue of the publication referred to
shall be applied.
National standards should be applied if Airbus standards are not available.
AIMS 04-05-000: Sealants – Technical specification
AIMS 04-05-001 Sealants – General purpose
AIMS 04-05-002 Sealants – Fuel tank
AIMS 04-05-003 Sealants – High temperature resistant
AIMS 04-05-005 Sealants – Non hardening jointing compounds
AIPS 01-02-008 Bolt torque tightening
AIPS 01-02-017 General assembly and installation of fasteners
AIPS 05-05-001 Sealing of aircraft structures
AIPS 09-01-002 Cleaning with Liquid non aqueous agents
EN9103 Quality management systems - Variation management of key characteristics

3 Definition, applicability and limitations

3.1 Definition
Application time Application time is the maximum period of time that a mixed sealant remains at a
consistency suitable for application. All sealant shall be applied before expiry of the
application time.

Assembly time Assembly time is the permitted period of time after mixing whereby a sealed joint must be
fastened to the required pre-load.

Class A sealant Suitable for brush application (overcoat sealant).

Class B sealant Suitable for application by extrusion-gun and spatula (fillet sealant).

Class C sealant Suitable for faying surface sealing (interfay sealant).

3.2 Applicability
This Airbus specification is applicable when invoked by the drawing directly or through another document for the
purpose given in the scope. When processing to AIPS05-05-004 is required, it shall be invoked on the drawing by
the words “Wet installation of fasteners” of AIPS 05-05-004. Process instructions shall not be called on drawing.

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3.3 Limitations of the process

High diameterical interference slug type rivets installed by automated equipment shall not be installed with sealant
or jointing compound.

Fasteners used in electrical bonding applications shall not be assembled with sealant on any contact faces. A
sealant overcoating however shall be required if specified on drawing.

When specified on drawing, non-hardening jointing compounds shall be used for the wet assembly of fasteners that
require regular removal in-service (access panels. etc).

4 Requirements

4.1 Technical requirements

4.1.1 Substrate condition

Surfaces to be assembled shall have the correct surface protections as specified on drawing.

All contact surfaces shall be free from dirt, swarf, grease or any other foreign contaminants.

All contact surfaces shall be dry before applying sealant.

Any residual lubricant as supplied on pre-lubricated fasteners shall not be removed.

4.1.2 Sealant preparation

Class C interfay sealant shall be selected for the wet installation of fasteners. If Class C sealant is not available
then it is permissible to use Class A overcoat sealant under authorization of M&P.

Sealant shall be prepared to the requirements of AIPS 05-05-001 unless otherwise specified on drawing.

4.1.3 Sealant application

Sealant shall be applied to the areas as specified in Appendix A unless otherwise specified on drawing.

Sealant shall be applied to substrate within the sealant application time.

Full sealant coverage of the specified contact face shall be achieved.

Unless otherwise specified on drawing or applicable documentation, interfay sealant shall not be applied to
washers and anchor nut for contact areas between washer and structure and/or anchor nut and structure.

4.1.4 Fastener installation

All fasteners shall be inserted within the sealant application time.

Fasteners shall be installed in a defined sequence to minimise possible joint relaxation. Where possible, threaded
nut and bolt type fasteners shall be check tightened at intervals within the sealant assembly time as per
AIPS 01-02-008.

The required fastener pre-load (eg. torque tightening requirement) shall be established within the sealant assembly
time.

Following installation, a full annular sealant exude shall be present around the head of the fastener to indicate
correct sealing and protection against corrosion.

Following installation, any excess sealant on rivet shank ends or bolt tails shall be removed with a clean cloth and
solvent as per AIPS 09-01-002.
Following installation, sealant on nut and bolt threads shall be removed with clean cloth without using any solvent.

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Any sealant contamination on component surfaces or nut/collar contact surfaces shall be removed with a clean
cloth and solvent as per AIPS 09-01-002.

Movement of the fastener within the assembly is not permitted if the sealant assembly time has expired. In cases
where the fastener has been disturbed outside the sealant assembly time then the fastener shall be removed.

4.1.5 Fastener oversealing

Fasteners with non self-sealing nuts in fuel tank boundaries shall be overcoated as per AIPS 05-05-001 or as
specified on drawing.

Blind fasteners within honeycomb structure shall be overcoated additionally with sealant as per AIPS 05-05-001.

4.1.6 Sealant integrity

The sealing of gaps and clearances between fasteners and components shall be such as to prevent leakage of any
liquid or gas being retained.

When required by drawing, leak testing shall only be performed after the sealant within the assembly has been
cured to the hardness requirements as specified in AIPS 05-05-001.

4.2 Quality requirements

4.2.1 Manufacturing shop

The manufacturing shop shall be approved to the requirements of the Airbus Quality Assurance Function for the
production and supply of parts assembled to this process.

4.2.2 Process
Installation processes shall be controlled within the limitations of this specification and the requirements contained
within section 4.1 shall be met.

Visual inspection of the installed fasteners shall ensure that gaps are completely filled, and that excess sealant has
been removed where required.

Pressurised leak testing shall be performed for fastener assemblies when specified on drawing.

4.2.3 Tooling/equipment
All tooling/equipment shall be obtained from controlled sources and shall be certified as suitable for intended use
and conforming to the requirements of this specification.

4.2.4 Personnel
All operators shall be fully trained to undertake the process.

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4.3 Key Characteristics

Key Characteristics acc. to EN9103 are defined by responsible engineering based on a risk analysis for parts
manufactured by this process. Key characteristics shall be defined on product level and if necessary also on
process level.
They shall be subject to variation control by production organization according to EN9103.
Key Characteristics do not relieve the production organization from meeting all engineering requirements defined in
this document.
Table 1: Key Characteristics

Product Key Characteristics Process Key Characteristics

Requirement/ Sub.- Requirement/
No. Designation Designation
Limit No. Limit

1 Surface preparation - 4.1.1

2 Sealant preparation - 4.1.2

Shall be defined in relevant AIPI
3 Sealant application - 4.1.3

4 Fastener installation - 4.1.4

5 Process qualification
For technical qualification: Refer to AIRBUS qualification procedure for Manufacturing Process.

For detailed qualification requirements refer to the relevant fastener installation AIPS.

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6 Appendix
Appendix A

Required locations of sealant application for the wet assembly of fasteners

Table A1 : Sealant location requirements for the wet assembly of fasteners

Fastener type Sealant applied on fastener Sealant applied on

under the on the fastener component (contact area
fastener head shank with fastener head)
Preformed solid and slug type
rivets -
Manual installation only Yes (1) Yes (2) Yes (1)
Automated installation only No No Yes (3)
Threaded and locking groove
fasteners - (4)
Clearance fit applications Yes (1) Yes Yes (1)
Interference fit applications Yes (1) No Yes (1)
Blind fasteners Yes Yes No

Notes:

(1) Sealant application is permitted under the fastener head or on the component at the discretion of the manufacturer unless otherwise
specified on drawing or within local specifications.
(2) Sealant is not permitted on tail prior to rivet setting.
(3) Sealant is not required in the case of slug rivets in wing skins.
(4) Sealant contamination on fastener thread or locking groove shall be avoided. Witnessing of sealant contamination shall be recorded and
referred to the Airbus Design Authority.

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RECORD OF REVISIONS

Clause
Issue Description of modification
modified

1 Whole New standard

03/97 document

2 Whole Standard modified to include A400M requirements

03/06 document

3 2 AIMS04-05-004 removed from Normative references

11/08
4.1.2 Change of sealant class, Introduction of new requirements

4.1.4 Note added reference sealant on nut / bolt threads.

4 4.3 Implementation of Key Characteristics

04/10

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