Sae Ams-S-8802d
Sae Ams-S-8802d
Sae Ams-S-8802d
D
AEROSPACE
MATERIAL SPECIFICATION Issued 1999-05
Revised 2015-12
Superseding AMS-S-8802C
RATIONALE
Removed Air Content, Radiographic Density, and minimum Flow requirements. Added heat conditioning prior to testing Low
Temperature Flexibility panels that was a requirement in MIL-S-8802. Aligned specification to current requirements in
AS5502 and AS5127/1. Changed accelerated cure requirements. Added an optional adhesion promoter requirement. Added
an alternative composite material (IM7/977-3). Added additional clarifications to current requirements and made editorial
corrections.
1. SCOPE
1.1 Form
This specification covers fuel-resistant, two-component polysulfide synthetic rubber compounds which cure at room
temperature.
1.2 Application
This sealing compound has been used typically for sealing and repairing integral fuel tanks, cabin pressure sealing, and
aerodynamic smoothing, but usage is not limited to such applications. It may be used for faying surface sealing, for wet-
installation of fasteners, for overcoating fasteners, and for sealing joints and seams. The sealing compound can be used in
fuel areas as well as in non-fuel areas. It may, in some cases, be used as a non-structural adhesive. The sealant is capable
of continuous service use from -65 to +250 °F (-54 to 121 °C). AMS3100 adhesion promoter may be applied prior to
application of the sealant.
1.3 Classification
1.3.1 Types
__________________________________________________________________________________________________________________________________________
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SAE INTERNATIONAL AMS-S-8802™D Page 2 of 13
1.3.2 Classes
The following classes apply to both Type 1 and Type 2 sealing compounds:
Class A - Suitable for application by brush. Available in the following application times in hours:
A-1/2
A-1
A-2
Class B - Suitable for application by extrusion gun or spatula. Available in the following application times in hours:
B-1/2
B-1
B-2
B-4
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Class C - Suitable for extrusion gun, spatula, brush, or roller. Available in the following application times in hours:
C-8(20)
C-8(48)
C-24(80)
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.
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.
AMS4045 Aluminum Alloy Sheet and Plate, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr, 7075: (-T6 Sheet, -T651 Plate), Solution
and Precipitation Heat Treated
AMS4911 Titanium Alloy, Sheet, Strip, and Plate, 6Al - 4V, Annealed
AMS5516 Steel, Corrosion-Resistant, Sheet, Strip, and Plate, 18Cr - 9.0Ni (SAE 30302) Solution Heat Treated
AMS-C-27725 Coating, Corrosion Preventative, for Aircraft Integral Fuel Tanks for Use to 250 °F (121 °C)
AS5127 Aerospace Standard Test Methods for Aerospace Sealants Methods for Preparing Aerospace Sealants
Test Specimens
MIL-DTL-81706 Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys
Available from Performance Review Institute, 161 Thorn Hill Road, Warrendale, PA 15086-7527, Tel: 724-772-1616,
www.pri-network.org.
3. TECHNICAL REQUIREMENTS
3.1 Materials
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The basic ingredient used in the manufacture of these products shall be polysulfide synthetic rubber. The sealing compound
shall cure by the addition of a curing agent to the base compound, and shall not depend on solvent evaporation for curing.
The material shall contain no lead compounds or leachable chromate compounds. The curing agent shall 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 sealant shall be red or pink in color.
3.4 Quality
Shelf life shall be a minimum of 9 months from the date of packaging. Material may be retested for shelf life extension per
4.3.3.
Premixed and frozen material shall have a minimum storage life of 30 days at -40 °F (-40 °C) or lower, or 10 days at -10 to
-40 °F (-23 to -40 °C) from the date of mix/freeze. Recommendations for longer storage lives at lower temperatures may be
provided by the manufacturer. 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 shall conform to the requirements shown in Table 1, when determined in
accordance with the specified test methods.
Test Procedures
Paragraph Property Requirement (Paragraph)
3.6.1 Nonvolatile Content, AS5127/1 (5.1)
by weight, min.
Class A 84%
Class B 90%
Class C 90%
3.6.5
C-8(20) 20 hours
C-8(48) 48 hours
C-24(80) 80 hours
Test Procedures
Paragraph Property Requirement (Paragraph)
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Test Procedures
Paragraph Property Requirement (Paragraph)
3.6.16 Shear Strength, min 200 psi (1379 kPa), AS5127/1 (7.8)
(Class C only) 95% cohesive failure
3.6.18 Peel Strength, min All 100% cohesive failure: AMS-S-8802 (4.6.2) and
AS5127/1 (8.1)
3.6.18.2 Class C
3.6.19 Fluid Immersed Peel Strength 10 lbf/inch (1750 N/m) AS5127/1 (8.1.3)
(Classes A-1/2 and B-1/2 only)
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Test Procedures
Paragraph Property Requirement (Paragraph)
3.6.21.1.7 Peel Strength: min, 2 aluminum 20 lbf/inch (3500 N/m) AS5127/1 (8.1)
panels, sulfuric acid anodized in /100% cohesive failure
accordance with AS5127 (6.3) and
coated with AMS-C-27725 Type 2
(see 8.4), After 7 days immersion in
AMS2629 Type 1 /3% salt water at
140 °F (60 °C).
B-2 64 hours
B-4 72 hours
Test Procedures
Paragraph Property Requirement (Paragraph)
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4.1.2 Sampling and Testing
Class B-2 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 classes or application times of the sealing compound.
Once qualification for Class B-2 has been obtained, other classes of the sealing compound and additional application times
of qualified classes may be qualified. The formulation for other classes, and for other application times of qualified classes,
shall be the same as Class B-2, except for minor variations necessary for conformance to viscosity and application time
requirements. All compounds shall meet all technical requirements of this specification. Other classes of the sealing
compound need only to be tested to the initial acceptance tests listed in 4.2.2, Resistance to Thermal Rupture (see 3.6.12),
all peel strength tests listed in Table 5, and other tests as defined by the QPL agency. 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 class and application time shall also be tested per PD2103.
Requirements shown in Table 2 are initial acceptance tests and shall be performed on each batch in accordance with
AS5502 (4.2.2.1).
Requirement
Test Paragraph
Nonvolatile Content 3.6.1
Viscosity of Base Compound1 3.6.2
Flow (Class B only) 3.6.3
Application Time 3.6.4
Assembly Time (Class C only) 3.6.5
Tack-Free Time (Classes A and B only) 3.6.6
Standard Cure Time 3.6.7
Fluid Immersion Cure Time (Classes A-1/2 and B-1/2 only) 3.6.8
Chalking 3.6.11
Shear Strength (Class C only) 3.6.16
Peel Strength: 3.6.18
2 aluminum panels, AMS4045, sulfuric
acid anodized in accordance with AS5127 (6.3), and
coated with AMS-C-27725 Type 2 (see 8.4) Condition for 7
days in AMS2629 Type 1 / 3% salt water).
1 Testing need not be performed on material packaged in sectionalized containers or
small size containers less than eight ounces (235 mL). Testing is required for
qualification testing.
Requirements shown in Table 3 are final acceptance tests and shall be performed on each lot of the final packaged product
in accordance with AS5502 (4.2.2.2).
Sample batches shall be produced using production scaled equipment. Enough material shall be supplied to perform all
required tests.
Sealing Compound, Fuel Resistant, Integral Fuel Tanks and Fuel Cell Cavities
AMS-S-8802D Type and Class
MANUFACTURER’S IDENTIFICATION
BATCH/LOT NUMBER
DATE OF PACKAGING
SHELF LIFE EXPIRATION DATE
STORE BELOW 80 °F (27 °C)
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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.
Sufficient material of each batch shall be prepared for initial and final acceptance testing and shall be packaged in the same
type containers that are being procured. After successful completion of the initial acceptance tests listed in Table 2, the
batch shall be released for final packaging. During packaging, test kits from each lot shall be selected at random for final
acceptance testing. Final acceptance testing shall 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
4.3.3 If a batch is being packaged in different types and/or size containers, the final acceptance tests on the lot 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.Shelf-Life Extension
Requirement
Test Paragraph
Viscosity of Base Compound 1 3.6.2
Flow (Class B only) 3.6.3
Application Time 3.6.4
Assembly Time (Class C only) 3.6.5
Tack-Free Time (Classes A and B only) 3.6.6
Standard Cure Time 3.6.7
Peel Strength 3.6.18
2 aluminum panels, AMS4045, sulfuric acid anodized in accordance
with AS5127 (6.3), coated with AMS-C-27725 Type 2 (see 8.4), and
aged in AMS2629 Type 1 for 7 days at 140 °F (60 °C).
1
Testing need not be performed on material packaged in sectionalized containers or
containers less than eight ounces (235 mL).
If tests are being performed at the end of the stated shelf life to extend the shelf-life of the sealing compound, and all tests
are passed, the shelf-life may be extended an additional three months. A maximum of three extensions are allowed.
4.4 Approval
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Unless otherwise specified herein, standard tolerances of AS5127 (3) “Standard Tolerances” shall apply.
Panels shall be prepared, cleaned, surface treated, and coated in accordance with AS5127 (6) prior to application of sealant
for testing.
Sealing compound shall be prepared in accordance with AS5127/1 (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.
When AMS3100 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.
Unless otherwise specified herein, freshly mixed sealing compound shall be applied to test panels in accordance with
AS5127 (6.10) “Application of Sealing Compound”. For Class A materials, the sealant may be applied in layers with a time
equal to the application life used between the applications to permit release of solvents.
Shall be tested in accordance with AS5127 (6.11) “Curing of Sealing Compounds”. The sealing compound shall be cured
for 14 days at Standard Conditions. For acceptance testing, the sealing compound may be given an accelerated cure for
48 hours, minimum at Standard Conditions followed by 24 hours, minimum at 140 °F (60 °C). For Class C-8(48), the sealing
compound may be given an accelerated cure for 48 hours, minimum at Standard Conditions followed by 48 hours, minimum
at 140 °F (60 °C). For Class C-24(80), the sealing compound may be given an accelerated cure for 48 hours, minimum at
Standard Conditions followed by 120 hours, minimum at 140 °F (60 °C).
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, two of the four panels shall be conditioned at 250 °F (121 °C) for an additional seven days. After
the conditioning, all four panels shall be immediately placed in a low temperature flexibility fixture and tested in accordance
with AS5127/1 (7.6).
The type and quantity of panels listed in Table 5 shall be used for the evaluation of peel strength. Test panel configuration
shall be in accordance with 4.5.3, AS5127/1 (8.1) “Peel Strength Testing” and AS5127/1 Figure 22 “Five-Inch Peel
Specimen Configuration”.
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Long Term Storage testing shall be conducted in accordance with AS5127/1 (9.2). The period of storage shall be 9 months.
Panel
Quantity Thickness,
Required Inch (mm) Panel Material Immersion Media at 140 °F (60 °C)
4 0.040 Al alloy AMS4045, chemical 2 panels in AMS2629 Type 1 for 7 days
(1.02) conversion coating per MIL-DTL- 2 panels in AMS2629 Type 1 / 3% salt water
81706 Class 1A Form II Method C for 7 days
4 0.040 Al alloy AMS4045, sulfuric acid 2 panels in AMS2629 Type 1 for 7 days
(1.02) anodized per AS5127 (6.3) 2 panels in AMS2629 Type 1 / 3% salt water
for 7 days
6 0.040 Al alloy AMS4045 sulfuric acid 2 panels in AMS2629 Type 1 for 7 days
(1.02) anodized per AS5127 (6.3), 2 panels in AMS2629 Type 1 / 3% salt water
overcoat of AMS-C-27725 Type 2 for 7 days
(see 8.4). 2 panels in AMS2629 Type 1 for 70 days with
fluid change every 14 days
8 0.040 Al alloy AMS4045 sulfuric acid 4 panels in 3% salt water for 7 days:
(1.02) anodized per AS5127 (6.3), 2 panels room temperature cured,
overcoat of MIL-PRF-23377 primer: 2 panels 200 °F (93 °C) cured.
4 panels cured 7 days at standard
conditions (4.5.2), 4 panels in distilled water for 7 days:
4 panels with primer, cured 2 hours 2 panels room temperature cured,
at 200 °F (93 °C). 2 panels 200 °F (93 °C) cured.
4.7 Reports
4.9 Qualification
Shall be in accordance with AS5502 (4.7). All products sold to this specification shall be listed, or approved for listing, on
the Qualified Products List, PRI-QPL-AMS-S-8802.
6. ACKNOWLEDGMENT
7. REJECTIONS
8. NOTES
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.
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 Sealing compounds meeting the requirements of this specification have been classified under Federal Supply
Classification (FSC) 8030.
8.4 For information purposes, DeSoto Coating 823-707 in accordance with AMS-C-27725 Type 2 is recommended for
use on peel strength test panels requiring the AMS-C-27725 coating.
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8.5 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.
8.6 Purchase documents should specify not less than the following:
AMS-S-8802D
Type and Class of sealing compound desired
Type and size of containers (kits) desired
Quantity of containers (kits) desired
Special packaging, if required.