**Process Specification for Dry-Film Lubricant Application**

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| **Engineering Directorate**                                           |
|                                                                       |
| **Structural Engineering Division**                                   |
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| **November 2002**                                                     |
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| ![](media/image1.png){width="1.3944444444444444in"                    |
| height="1.1430555555555555in"}                                        |
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| National Aeronautics and                                              |
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| Space Administration                                                  |
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| **Lyndon B. Johnson Space Center**                                    |
|                                                                       |
| Houston, Texas                                                        |
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**Process Specification for Dry-Film**

**Lubricant Application**

+-----------------+---------------------------------+------+-----------+
| **Prepared      | ###### Signature on File        |      | 10/21/02  |
| by:**           |                                 |      |           |
+-----------------+---------------------------------+------+-----------+
|                 | Julie A. Henkener               |      | Date      |
|                 |                                 |      |           |
|                 | Materials and Processes         |      |           |
|                 | Branch/ES4                      |      |           |
+-----------------+---------------------------------+------+-----------+
|                 | ***Signature on File***         |      | 10/21/02  |
+-----------------+---------------------------------+------+-----------+
| **Approved      | Jose Hernandez, Acting Chief    |      | Date      |
| by:**           |                                 |      |           |
|                 | Materials and Processes         |      |           |
|                 | Branch/ES4                      |      |           |
+-----------------+---------------------------------+------+-----------+
|                 |                                 |      |           |
+-----------------+---------------------------------+------+-----------+

  ----------- --------------------------------------------- ---------------
  REVISIONS                                                 

  VERSION     CHANGES                                       DATE

  \--         Original version                              5/14/96

  A           New format, title change, author change,      7/26/99
              re-wrote section 2.0, expanded section 3.0,   
              specified 220 mesh alumina for grit blasting  
              Ni alloys and stainless steels, made          
              burnishing standard, revised storage time     
              limits in section 6.1.3.                      

  B           Changed EM references to ES, clarified        11/14/02
              passivation requirements for nickel-based and 
              stainless steel alloys.                       

                                                            

                                                            
  ----------- --------------------------------------------- ---------------

**1.0 [SCOPE]{.underline}**

This process specification establishes requirements for the application
of resin-bonded and sodium-silicate-bonded dry-film lubricants to
metallic parts used in flight hardware manufactured by JSC.

**2.0 [APPLICABILITY]{.underline}**

This process specification applies to the following resin-bonded and
sodium-silicate bonded dry-film lubricants: Everlube 620C, Everlube 811,
Everlube 812, and Tiolube 460. Specifically, it addresses the spray
application of these lubricants and their cure at elevated temperature.

**3.0 [USAGE]{.underline}**

This process specification shall be called out on the engineering
drawing by identifying the surface(s) to be coated and using a drawing
note that identifies the lubricant. One example of the standard callout
is:

**APPLY EVERLUBE 620C DRY-FILM LUBRICANT PER NASA/JSC PRC-8001**

This specification controls the thickness and curing time/temperature
(see sections 6.2 and 6.3) for the dry-film lubricants listed. For
lubricants not listed in this specification, the material, thickness,
and curing time and temperature shall be called out in a manner similar
to the following example:

**APPLY** *{lubricant manufacturer's designation}* **DRY-FILM LUBRICANT
PER NASA/JSC PRC-8001, COATING THICKNESS 0.0003 to 0.0006 INCHES. CURE
AT 375 [+]{.underline} 10 F FOR 65 [+]{.underline} 5 MINUTES.**

Burnishing of the cured dry film coating is standard. If a burnished
coating is not desired, a note of **"DO NOT BURNISH"** shall be included
on the drawing.

It is difficult or impossible to apply dry film lubricant with a uniform
thickness on internal surfaces and radii. Functional surfaces shall be
marked for coating. Other surfaces should be flagged as **"OVERSPRAY
ACCEPTABLE"** or **"NO DRY FILM ON THIS SURFACE"**.

The lubricant, and its material specification (if applicable), shall be
called out in the parts list similar to the following:

  ------------------ -------------------- ------------- -----------------
  Part number        Description          Material      Specification

                                                        

  Everlube 620C      Dry Film Lubricant                 

                                                        

  Tiolube 460        Dry Film Lubricant                 

                                                        

  Everlube 811       Dry Film Lubricant                 MIL-L-81329

                                                        

  Everlube 812       Dry Film Lubricant                 MIL-L-81329
  ------------------ -------------------- ------------- -----------------

Everlube products are manufactured by the E/M Corporation, and Tiolube
products are manufactured by the Tiodize Corporation.

When a dry-film lubricant is required on an aluminum alloy component,
the aluminum must be previously anodized. Anodic coatings shall be
specified on the drawing according to PRC-5006. For nickel-based and
stainless steel alloys, the entire component must be passivated per
PRC-5002 prior to grit blasting the region where the dry film lubricant
will be applied. Passivation can be waived only if every surface of the
component will have dry film lubricant applied. More detailed
requirements for surface preparation are found in section 6.1.2.

Dry film lubricants are mechanically bonded to metal surfaces and these
surfaces must be roughened to promote adhesion of the dry-film
lubricant. This is normally accomplished by abrasive blasting of the
surface before coating. For best adhesion and wear resistance, the
surface roughness, Rq, of the surface to be coated with dry-film
lubricant should normally be specified on the engineering drawing to be
"at but not better than" 32 rms (nominally). Usually this is
accomplished with a drawing note pointing to the specific surface
involved and indicating the surface roughness. A surface roughness as
low as 16 rms (nominal) may often be specified without affecting
adhesion significantly, but the abrasive blasting may increase the
roughness. Surface roughness will typically normalize to 32 rms after
blasting. However, a very flat smooth surface that is lightly abraded
will still have a flat topped surface that, when coated with dry film
lubricant, should still meet most functional requirements. Special
requirements for lower surface roughness and finer abrasives will
require additional process development time and test specimens to
qualify the new techniques.

## 3.1 WORK INSTRUCTIONS

Work instructions shall be generated for implementing this process
specification. The work instructions shall contain sufficient detail to
ensure that the manufacturing process produces consistent, repeatable
products that comply with this specification.

**4.0 [REFERENCES]{.underline}**

ANSI B46.1 *Surface Texture Surface Roughness, Waviness and* *Lay*

ASTM F22 *Standard Test Method for Hydrophobic Surface Films by the
Water Break Test*

DOD-P-16232 *Phosphate Coatings, Heavy, Manganese or Zinc Base*

MIL-L-46010 *Lubricant, Solid Film, Heat Cured, Corrosion Inhibiting*

MIL-L-81329 *Lubricant, Solid Film, Extreme Environment*

Tech Data *Everlube 620C (E/M Lubricants, Inc.)*

##### Sheet 2014

Tech Data *Everlube 811 (E/M Lubricants, Inc.)*

Sheet 2050

Tech Data *Everlube 812 (E/M Lubricants, Inc.)*

Sheet 2055

Bulletin 460/588 *Tiolube 460 (Tiodize Company, Inc.)*

**5.0 [MATERIAL REQUIREMENTS]{.underline}**

None identified.

**6.0 [PROCESS REQUIREMENTS]{.underline}**

**6.1 PRE-LUBRICANT SURFACE PREPARATION**

The surfaces to be lubricated shall meet the following requirements:

**6.1.1 [Smoothness]{.underline}**

The surface roughness shall be verified to be as-specified on the
engineering drawing before any surface pretreatment. A surface finish
nominally higher or lower than specified is cause for rejection.

**6.1.2 [Surface Pretreatment]{.underline}**

The surface to be coated shall be pretreated as follows:

\(a\) Aluminum Alloys - glass bead peen followed by anodic coating per
PRC-5006, Type II or Type III

\(b\) Nickel-base Alloys and Stainless Steels (plated or unplated) --
passivate per PRC-5002 followed by grit blasting. If all surfaces of the
component will have dry film lubricant applied, passivation can be
waived.

\(c\) Titanium - grit blast using materials approved for use on
titanium.

\(d\) Steels - grit blast followed by phosphate coating per MIL-P-16232,
type M

6.1.2.1 [Glass Bead Peening]{.underline}

Aluminum surfaces shall be glass bead peened with 80/120 glass bead. The
blaster pressure and distance from the surface shall be controlled to
obtain the required surface roughness without removing a significant
quantity of material.

6.1.2.2 [Grit Blasting]{.underline}

Nickel-base and stainless steel alloy surfaces shall be grit blasted
with 220 mesh clean dry alumina in order to obtain good surface adhesion
of the bonded dry-film lubricant. Steel alloys shall use 220 mesh clean
dry alumina. The blaster pressure and distance from the surface shall be
controlled to obtain the required surface roughness without rounding
radii or removing a significant quantity of material. The surface
roughness will usually normalize to approximately 32 Ra during grit
blasting (verified during qualification), unless an alternate grit or
media is specified on the engineering drawing.

3.  [Solvent Cleaning]{.underline}

After glass bead peening or grit blasting, parts shall be cleaned.
Cleaning may use any technique capable of removing particulate and
organic surface contamination. The cleaning shall be finished with a
non-filming solvent. The cleaning process, specific to material group
and pretreatment method, shall be capable of passing a 30 second ASTM
F22 water break test.

**6.1.3 [Prepared Surface Storage Requirements and Time
Limits]{.underline}**

If the lubricant is not to be applied immediately, the prepared surface
should be protected against contamination and corrosion.

To minimize oxidation and corrosion, the maximum elapsed time between
surface pretreatment and lubricant application shall be as follows:

\(a\) Aluminum Alloys - 8 Hours

\(b\) Nickel-Base Alloys and Corrosion Resistant Steels - 8 hours

\(c\) Titanium - 8 Hours

\(d\) Steel - 8 hours

The time limit for pre-treated parts may be extended indefinitely if
stored in a humidity controlled (\<40%) environment or stored with
non-dusting desiccants. In addition, the time limit may be extended
indefinitely for pre-treated parts that are stored in a dry, clean argon
or nitrogen environment.

**6.1.4 [In-Process Rework]{.underline}**

Parts surface treated per 6.1.2 that exceed the specified time
limitations of 6.1.3 shall be completely reprocessed.

5.  **[Surface Condition]{.underline}**

Surfaces shall be examined before application of the lubricant. The
surface condition shall be uniform in appearance and free from visible
defects such as nicks, scratches, burrs, or other surface
irregularities. There shall be no evidence of grease, oil, grit,
tarnish, rust, scale, corrosion or other contaminants when wiped with a
clean white cloth.

**6.2 DRY-FILM LUBRICANT THICKNESS**

The dry-film lubricant thickness shall be as specified below. For
lubricants not listed below, the thickness shall be as-specified on the
engineering drawing.

Everlube 620C 0.0003 to 0.0005 inches

Everlube 811 and Everlube 812 0.0003 to 0.0005 inches

Tiolube 460 0.0003 to 0.0005 inches

**6.3 CURE TIME AND TEMPERATURE**

The time/temperature cycle needed to cure the lubricant shall be
as-listed below. For lubricants not listed, the cure time and
temperature shall be as-specified on the engineering drawing.

**Everlube 620C:**

\(a\) Aluminum Alloys 300 [+]{.underline} 10 F for 65 [+]{.underline} 5
minutes

\(b\) Ni-Based Alloys, Stainless Steels 375 [+]{.underline} 10 F for 65
[+]{.underline} 5 minutes

\(c\) Titanium Alloys 375 [+]{.underline} 10 F for 65 [+]{.underline} 5
minutes

\(d\) Steel Alloys 375 [+]{.underline} 10 F for 65 [+]{.underline} 5
minutes

**Everlube 811 and Everlube 812:**

\(a\) Aluminum Alloys 325 [+]{.underline} 10 F for 2.5 to 3 hours

\(b\) Ni-Based Alloys, Stainless Steels 400 [+]{.underline} 10 F for 2
to 3 hours

\(c\) Titanium Alloys 400 [+]{.underline} 10 F for 2 to 3 hours

\(d\) Steel Alloys 400 [+]{.underline} 10 F for 2.5 to 3 hours

**Tiolube 460:**

\(a\) Ni-Based Alloys, Stainless Steels 400 [+]{.underline} 10 F for 65
[+]{.underline} 5 minutes

\(b\) Titanium Alloys 400 [+]{.underline} 10 F for 65 [+]{.underline} 5
minutes

\(c\) Steel Alloys 400 [+]{.underline} 10 F for 65 [+]{.underline} 5
minutes

**Note:** A 15-minute flash-bake at 150F is required before the start of
oven curing. After the flash-bake, the part may remain in the oven
during ramp-up to final curing temperature. In no case shall processing
be performed at a temperature that would adversely affect the properties
of substrate metals. The cure times in this specification are
representative of the time that the coated part is at temperature.

**6.4 BURNISHING**

Unless specified otherwise on the engineering drawing, the cured
dry-film coating shall be burnished with a clean white cloth, using
light hand pressure until the surface takes on a glossy metallic sheen.

**7.0 [PROCESS QUALIFICATION]{.underline}**

The bonded dry-film lubricant process shall be qualified on sample
plates for each metal pretreatment type to assure effectiveness prior to
application on production parts. Qualification shall show that the
process (including pre-treatment) is capable of meeting all requirements
of this specification. Any change in processing parameters or lubricant
material will require requal-ification.

**8.0 [PROCESS VERIFICATION]{.underline}**

**8.1 APPEARANCE**

When visually examined in its finished form, at least 95 percent of the
bonded lubricant coating shall appear uniform and smooth, free from
cracks, scratches, blisters, bubbles, runs, sags, foreign matter, grit,
rough particles, separation of ingredients or other surface
imperfections. The remaining area shall be free of burrs and other
imperfections detrimental to lubricity.

**8.2 FILM ADHESION**

The bonded lubricant shall show good adhesion to the prepared surface
using a tape peel test (Scotch 250 tape or equivalent is removed in one
abrupt motion). A uniform deposit of powdery material may adhere to the
tape, but the lifting of any flakes or lubricant particles that expose
any part of the surface under the dry-film lubricant is unacceptable.

**8.3 SOLVENT WIPE TEST**

Resin-bonded dry-film lubricants shall show good adhesion to the
prepared surface when subjected to the following solvent wipe test. Cure
shall be determined for each lot of items processed at one time on the
lubricated parts. The lubricant shall be wiped using a clean, cotton
swab that is saturated with methyl ethyl ketone solvent. Each surface
shall be wiped a minimum of 50 strokes in a 1 square inch surface area.
A uniform transfer of material may adhere to the cotton swab, but the
removal of flakes or lubricant particles that expose any part of the
surface under the dry-film lubricant is unacceptable.

Sodium-silicate bonded dry-film lubricants do not require this solvent
wipe test.

**8.4 DRY-FILM LUBRICANT THICKNESS**

The application process shall be controlled to ensure the coating
thickness is within specification. If process control is insufficient to
ensure a repeatable coating of the required thickness, the thickness
shall be determined for each lot of items processed at one time, either
on test specimens or the actual lubricated parts. The following methods
are acceptable: eddy-current thickness gage, magnetic induction
thickness gage, the difference in lubricated and pretreated measurements
using a height gage with 0.0001 inch measuring capabilities, or other
equivalent measurement equipment that does not compress the coating
during measurement.

**9.0 [TRAINING AND CERTIFICATION OF PERSONNEL]{.underline}**

All bonded dry-film lubricant operations shall be performed by personnel
who have been trained for this process and have successfully performed a
coating qualification to this specification.

**10.0 [DEFINITIONS]{.underline}**

Ra Measure of roughness of a surface, defined as the arithmetic average
deviation of a surface from the centerline of that surface.

Rq Measure of roughness of a surface, defined as the root-mean-square
deviation of a surface from the centerline of that surface.