Mil STD 1568d

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com
INCH-POUND
MIL-STD-1568D
31 August 2015
SUPERSEDING
MIL-STD-1568C
12 August 2014
DEPARTMENT OF DEFENSE
DESIGN CRITERIA STANDARD
MATERIALS AND PROCESSES FOR
CORROSION PREVENTION AND CONTROL IN
AEROSPACE WEAPONS SYSTEMS
AMSC 9572 AREA MFFP

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MIL-STD-1568D
FOREWORD
1. This standard is approved for use by all Departments and Agencies of the Department of
Defense.
2. Comments, suggestions, or questions on this document should be addressed to:

Commander, Naval Air Warfare Center, Aircraft Division, Route 547, Mail Stop 120-3,
Code 4.1.2, Joint Base MDL, NJ 08733-5100, or emailed to [email protected].
Since contact information can change, you may want to verify the currency of this
address information using the ASSIST Online database at https://assist.dla.mil.
3. For guidance on the technical content of this document, contact Commander, Naval Air
Warfare Center, Aircraft Division, (Code 4.3), 48066 Shaw Road, 2188 Patuxent River,
MD 20670.
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MIL-STD-1568D
TABLE OF CONTENTS
Paragraph Page
FOREWORD ........................................................................................................................... ii
1. SCOPE ........................................................................................................................... 1
1.1 Scope ........................................................................................................................... 1
1.2 Purpose ........................................................................................................................... 1
1.3 Applicability ........................................................................................................................... 1
2. APPLICABLE DOCUMENTS .................................................................................................... 2

2.1 General ........................................................................................................................... 2
2.2 Government documents .............................................................................................................. 2
2.2.1 Specifications, standards, and handbooks ................................................................................ 2
2.2.2 Other Government documents, drawings, and publications .................................................... 3
2.3 Non-Government publications .................................................................................................... 4
2.4 Order of precedence .................................................................................................................... 7
3. DEFINITIONS ........................................................................................................................... 7
3.1 Aerospace weapons systems ....................................................................................................... 7
3.2 Aircraft structure ......................................................................................................................... 7
3.3 Alternate manufacturing processes ............................................................................................. 7
3.4 Cognizant Engineering Authority (CEA) ................................................................................... 7
3.5 Corrosion ........................................................................................................................... 7
3.6 Corrosion Prevention and Control (CPC) ................................................................................... 7
3.7 Corrosion Prevention and Control Plan (CPCP)......................................................................... 8
3.8 Corrosion prevention and control planning ................................................................................ 8
3.9 Corrosion Prevention Team (CPT) ............................................................................................. 8
3.10 Critical surface/part ................................................................................................................... 8
3.11 Damage ........................................................................................................................... 8
3.12 Durability ........................................................................................................................... 8
3.13 Erosion ........................................................................................................................... 8
3.14 Exterior surfaces ....................................................................................................................... 8
3.15 Microbially Influenced Corrosion (MIC) ................................................................................. 8
3.16 Nondestructive Inspection (NDI) .............................................................................................. 8
3.17 Stress Corrosion Cracking (SCC) ............................................................................................. 9
3.18 Structural integrity .................................................................................................................... 9
3.19 Supportability ........................................................................................................................... 9
3.20 Sustainment ........................................................................................................................... 9
3.21 Wear ........................................................................................................................... 9
4. GENERAL REQUIREMENTS .................................................................................................... 9

4.1 Corrosion Prevention and Control Plan (CPCP)......................................................................... 9
4.2 Finish specification ..................................................................................................................... 10
4.3 Sustainment ........................................................................................................................... 10
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Paragraph Page
4.4 Materials and process considerations in design .......................................................................... 10

4.4.1 Selection considerations........................................................................................................... 10
4.4.2 Guided missiles and rocket systems ........................................................................................ 11
4.4.3 Alternate manufacturing processes .......................................................................................... 11
4.5 General design requirements for corrosion prevention ............................................................... 11
4.5.1 Exclusion of rain and airborne spray ....................................................................................... 11
4.5.2 Ventilation ........................................................................................................................... 11
4.5.3 Drainage ........................................................................................................................... 11
4.5.4 Galvanically dissimilar materials ............................................................................................. 11
4.5.5 Insulation/acoustic blankets ..................................................................................................... 11
4.5.6 Nondestructive inspection (NDI) for corrosion ....................................................................... 12
4.5.6.1 NDI methodologies and techniques ...................................................................................... 12
4.6 Metallic materials........................................................................................................................ 12
4.6.1 Aluminum ........................................................................................................................... 12
4.6.1.1 Alloy selection ...................................................................................................................... 12
4.6.1.2 Aluminum alloy selection limitations ................................................................................... 14
4.6.1.3 Maximum metal removal ...................................................................................................... 14
4.6.1.4 Clad aluminum sheet............................................................................................................. 14
4.6.1.5 Compressive residual surface stress for corrosion resistance and fatigue life
improvement ........................................................................................................................... 14
4.6.1.6 Stress corrosion factor........................................................................................................... 15
4.6.1.7 Aluminum lithium (A1-Li) alloys (special considerations) .................................................. 15
4.6.2 Steels ........................................................................................................................... 15
4.6.2.1 Low alloy, high strength steels ............................................................................................. 15
4.6.2.2 Stress corrosion factors ......................................................................................................... 16
4.6.2.3 Corrosion resistant steels (CRES)......................................................................................... 16
4.6.2.3.1 Corrosion resistant steel limitations ................................................................................... 16
4.6.2.4 Titanium ........................................................................................................................... 17
4.6.2.4.1 Surface considerations ....................................................................................................... 17
4.6.2.4.2 Fretting ........................................................................................................................... 17
4.6.2.4.3 Special precautions ............................................................................................................ 18
4.6.2.4.4 Titanium contamination ..................................................................................................... 18
4.6.2.5 Magnesium ........................................................................................................................... 18
4.6.2.6 Beryllium and aluminum-beryllium alloys ........................................................................... 18
4.6.2.7 Mercury ........................................................................................................................... 18
4.6.2.8 Depleted uranium .................................................................................................................. 18
4.6.2.9 Tin and tin alloys .................................................................................................................. 18
4.6.2.10 Bronze bearing alloys ......................................................................................................... 18
4.6.3 Organic materials ..................................................................................................................... 18
4.6.4 Composites ........................................................................................................................... 19
4.6.5 Corrosion prevention during manufacturing operations and storage ....................................... 19
4.6.6 Cleaning ........................................................................................................................... 19
4.6.7 Surface damage ........................................................................................................................ 19
4.6.8 Marking pencils ....................................................................................................................... 19
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MIL-STD-1568D
Paragraph Page
4.6.9 Protection of parts during storage and shipment...................................................................... 19

4.6.9.1 Storage and shipping preservatives ....................................................................................... 20
4.6.10 Inorganic finishes ................................................................................................................... 20
4.6.10.1 Cadmium coatings .............................................................................................................. 20
4.6.10.2 Aluminum coatings ............................................................................................................. 20
4.6.10.3 Nickel plating ...................................................................................................................... 20
4.6.10.3.1 Undercoating .................................................................................................................... 20
4.6.10.4 Zinc plating ......................................................................................................................... 20
4.6.10.5 Chromium plating ............................................................................................................... 21
4.6.11 Organic finishes ..................................................................................................................... 21
4.6.11.1 Organic finishes and systems (for Air Force systems) ....................................................... 21
4.6.11.2 Fire insulating paint ............................................................................................................ 21
4.6.12 Environmental sealing ........................................................................................................... 21
4.6.13 Fastener installation ............................................................................................................... 22
4.6.13.1 Fasteners in titanium ........................................................................................................... 22
4.6.13.2 Fasteners in graphite composites ........................................................................................ 22
4.6.13.3 Monel and stainless steel fasteners ..................................................................................... 22
4.6.13.4 Interference fit fasteners ..................................................................................................... 22
4.6.14 Special considerations ............................................................................................................ 22
4.6.14.1 Signature control ................................................................................................................. 22
4.6.14.2 Fluids, lubricants and their containment ............................................................................. 22
4.6.14.3 Greases ........................................................................................................................... 22
4.6.14.4 Coolant ........................................................................................................................... 23
4.6.14.5 Fluorocarbon seals .............................................................................................................. 23
4.6.15 Electronic or avionics systems ............................................................................................... 23
4.6.16 Firefighting agents ................................................................................................................. 23
4.6.17 Wear and erosion ................................................................................................................... 23
4.6.18 Lubrication ........................................................................................................................... 23
4.6.19 Support equipment ................................................................................................................. 23
4.6.20 Welded components ............................................................................................................... 23
4.7 Verification of corrosion design ................................................................................................. 23
4.7.1 Engine corrosion testing .......................................................................................................... 24
5. DETAIL REQUIREMENTS ........................................................................................................ 25
6. NOTES ........................................................................................................................... 25
6.1 Intended use ........................................................................................................................... 25
6.2 Acquisition requirements ............................................................................................................ 25
6.3 Associated Data Item Descriptions (DIDs)................................................................................. 26
6.4 Subject term (key word) listing................................................................................................... 26
6.5 Alternate materials and processes ............................................................................................... 26
6.6 Document websites and historical information websites ............................................................ 26
6.7 Changes from previous issue ...................................................................................................... 26
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MIL-STD-1568D
CONCLUDING MATERIAL .......................................................................................................... 33
TABLES
I. Rating for resistance to SCC aluminum alloys in the short transverse grain
direction (STDG) ....................................................................................................................... 13
II. Corrosion characteristics of corrosion resistant steels............................................................... 17
III. Corrosion protective coatings verification ................................................................................. 24
APPENDICES
A. CORROSION PREVENTION AND CONTROL PLAN (CPCP) AND FINISH

SPECIFICATION...................................................................................................................... 27
B. CORROSION PREVENTION TEAMS (CPTs) ....................................................................... 28
C. MISCELLANEOUS FACTORS AFFECTING CORROSION ................................................ 31
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MIL-STD-1568D
1. SCOPE
1.1 Scope. This standard establishes the requirements for materials, processes and
techniques, and identifies the tasks required to implement an effective corrosion prevention and
control program throughout the conceptual, validation, development, production, and
sustainment phases of the aerospace weapons systems life cycle. Applicable systems include
fixed wing aircraft, unmanned aerial vehicles, space vehicles, rotorcraft, missile systems, air
delivered guided munitions, and all related ground support equipment. Meeting or exceeding the
requirements of this standard, as well as applicable program-specific technical documentation,
will facilitate an optimum balance between acquisition and sustainment costs for DoD aerospace
weapons systems, and ultimately enhance system reliability, supportability, and safety. Authority
to exceed or amend the requirements in this standard requires permission from the Cognizant
Engineering Authority (CEA).
1.2 Purpose. The purpose of this standard is to provide a mechanism for implementation of
sound materials selection practices and finish treatments during the design, development,
production and operational (sustainment) cycles of aerospace weapons systems. This standard
defines technical requirements to ensure establishment and implementation of a corrosion
prevention and control plan and its accompanying finish specification. The corrosion prevention
and control plan will set up operating procedures and the finish philosophies used in the systems.
The finish specification details the finish and coating systems to be used on the respective
aerospace weapons system in accordance with the finish philosophies as approved in the
corrosion prevention and control plan. This standard is derived from experience gained on
protection of aerospace weapons systems against corrosion by the military services and industry.
1.3 Applicability. This standard is applicable for the Department of Defense procuring
activities and their respective contractors involved in the design and procurement of aerospace
weapons systems, including spares, upgrades, and major repairs.
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MIL-STD-1568D
2. APPLICABLE DOCUMENTS
2.1 General. The documents listed in this section are specified in sections 3, 4 or 5 of this
standard. This section does not include documents cited in other sections of this specification or
recommended for additional information or as examples. While every effort has been made to
ensure the completeness of this list, document users are cautioned that they must meet all
specified requirements of documents cited in sections 3, 4, or 5 of this standard, whether or not
they are listed.
2.2 Government documents.
2.2.1 Specifications, standards, and handbooks. The following specifications, standards,

and handbooks form a part of this document to the extent specified herein. Unless otherwise
specified, the issues of these documents are those cited in the solicitation or contract.
FEDERAL SPECIFICATIONS
TT-C-490 - Chemical Conversion Coatings and Pretreatments for

Metallic Substrates (Base for Organic Coatings)
TT-P-2760 - Primer Coating Polyurethane, Elastomeric, High-Solids
DEPARTMENT OF DEFENSE SPECIFICATIONS
MIL-DTL-5002 - Surface Treatments and Inorganic Coatings for Metal

Surfaces of Weapons Systems
MIL-PRF-8516 - Sealing Compound, Synthetic Rubber, Electric Connectors,
And Electric Systems, Chemically Cured
MIL-DTL-18264 - Finishes, Organic, Weapons Systems, Application and
Control of
MIL-PRF-23377 - Primer Coatings: Epoxy, High-Solids
MIL-PRF-23586 - Sealing Compound (With Accelerator), Silicone Rubber,
Electrical
MIL-M-24041 - Molding and Potting Compound, Chemically Cured,
Polyurethane
MIL-PRF-27617 - Grease, Aircraft and Instrument, Fuel and Oxidizer Resistant
MIL-PRF-32014 - Grease, Aircraft and Instrument
MIL-PRF-32239 - Coating System, Advanced Performance, for Aerospace
Applications
MIL-M-38510 - Microcircuits, General Specification for
MIL-A-46146 - Adhesives-Sealants, Silicone, RTV, Noncorrosive (for use
with Sensitive Metals and Equipment)
MIL-PRF-46170 - Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic
Hydrocarbon Base, NATO Code No. H-544
MIL-PRF-81733 - Sealing and Coating Compound, Corrosion Inhibitive
MIL-PRF-81322 - Grease, Aircraft, General Purpose, Wide Temperature Range,
NATO Code G-395
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MIL-STD-1568D
MIL-PRF-83282 - Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon Base,

Metric, NATO Code Number H-537
MIL-DTL-83488 - Coating, Aluminum, High Purity
MIL-PRF-85285 - Coating: Polyurethane, Aircraft and Support Equipment
MIL-PRF-85582 - Primer Coatings: Epoxy, Waterborne
MIL-PRF-87252 - Coolant Fluid, Hydrolytically Stable, Dielectric
MIL-PRF-87257 - Hydraulic Fluid, Fire Resistant; Low Temperature,
Synthetic Hydrocarbon Base, Aircraft and Missile
DEPARTMENT OF DEFENSE STANDARDS
MIL-STD-186 - Protective Finishing For Army Missile Weapon Systems

MIL-STD-866 - Grinding of Chrome Plated Steel and Steel Parts Heat
Treated to 180,000 PSI or Over
MIL-STD-889 - Dissimilar Metals
MIL-STD-1500 - Cadmium-Titanium Plating, Low Embrittlement,
Electrodeposition
MIL-STD-2073-1 - Standard Practice for Military Packaging
MIL-STD-3021 - Materials Deposition, Cold Spray
MIL-STD-7179 - Finishes, Coatings and Sealants for the Protection of
Aerospace Weapons Systems
DEPARTMENT OF DEFENSE HANDBOOKS
MIL-HDBK-275 - Guide for Selection of Lubricants, Fluids, and Compounds

for Use in Flight Vehicles and Components
MIL-HDBK-808 - Finish, Protective and Codes for Finishing Schemes for
Ground and Ground Support Equipment
MIL-HDBK-838 - Lubrication of Military Equipment
MIL-HDBK-1250 - Corrosion Prevention and Deterioration Control
In Electronic Components and Assemblies
MIL-HDBK-6870 - Nondestructive Inspection Program Requirements for
Aircraft and Missile Materials and Parts
(Copies of these documents are available online at https://assist.dla.mil.)
2.2.2 Other Government documents, drawings, and publications. The following other
Government documents, drawings, and publications form a part of this document to the extent
specified herein. Unless otherwise specified, the issues of these documents are those cited in the
solicitation or contract.
DEFENSE DIRECTIVE
DoDD 5000.01 - The Defense Acquisition System
(Copies of this document are available online at http://www.dtic.mil.)
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MIL-STD-1568D
GUIDEBOOK
Corrosion Prevention and Control Planning Guidebook for Military Systems and
Equipment
(Copies of this document are available online at

https://www.corrdefense.org/External/ReferenceLibrary.aspx.)
DEFENSE FEDERAL ACQUISITION REGULATION SUPPLEMENT (DFARS)
Subpart 207.105 - Acquisition Planning: Contents of Written Acquisition Plans
(Copies of these documents are available at http://www.dcaa.mil/dfars.html.)
2.3 Non-Government publications. The following documents form a part of this document
to the extent specified herein. Unless otherwise specified, the issues of these documents are
those cited in the solicitation or contract.
ASTM INTERNATIONAL
ASTM A380/A380M - Standard Practice for Cleaning, Descaling, and Passivation of

Stainless Steel Parts, Equipment, and Systems
ASTM B30 - Standard Specification for Copper Alloys in Ingot Form
ASTM B66 - Standard Specification for Bronze Castings for Steam
Locomotive Wearing Parts
ASTM B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM B148 - Standard Specification for Aluminum-Bronze Sand Castings
ASTM B150/B150M - Standard Specification for Aluminum Bronze Rod, Bar, and
Shapes
ASTM B169/B169M - Standard Specification for Aluminum Bronze Sheet, Strip,
and Rolled Bar
ASTM B194 - Standard Specification for Copper-Beryllium Alloy Plate,
Sheet, Strip, and Rolled Bar
ASTM B196/B196M - Standard Specification for Copper-Beryllium Alloy Rod and
Bar
ASTM B197/B197M - Standard Specification for Copper-Beryllium Alloy Wire
ASTM B271/B271M - Standard Specification for Copper-Base Alloy Centrifugal
Castings
ASTM B505/B505M - Standard Specification for Copper Alloy Continuous
Castings
ASTM B600 - Standard Guide for Descaling and Cleaning Titanium and
Titanium Alloy Surfaces
ASTM B763/B763M - Standard Specification for Copper Alloy Sand Castings for
Valve Applications
ASTM B806 - Standard Specification for Copper Alloy Permanent Mold
Castings for General Applications
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MIL-STD-1568D
ASTM D2247 - Standard Practice for Testing Water Resistance of Coatings

in 100% Relative Humidity
ASTM D2803 - Standard Guide for Testing Filiform Corrosion Resistance of
Organic Coatings on Metal
ASTM F519 - Standard Test Method for Mechanical Hydrogen
Embrittlement Evaluation of Plating/Coating Processes and
Service Environments
ASTM G47 - Standard Test Method for Determining Susceptibility to
Stress Corrosion Cracking of 2XXX and 7XXX Aluminum
Alloy Products
ASTM G58 - Standard Practice for Preparation of Stress-Corrosion Test
Specimens for Weldments
ASTM G64 - Standard Classification of Resistance to Stress Corrosion
Cracking of Heat-Treatable Aluminum Alloys
ASTM G85 - Standard Practice for Modified Salt Spray (Fog) Testing
(Copies of these documents are available online at http://www.astm.org.)
IPC Association Connecting Electronics Industries
J-STD-001 - Requirements For Soldered Electrical And Electronic

Assemblies (DoD adopted)
(Copies of this document are available online at http://www.ipc.org.)
SAE INTERNATIONAL
SAE AMS-QQ-N-290 - Nickel Plating (Electrodeposited)

SAE AMS-QQ-P-416 - Plating, Cadmium (Electrodeposited)
SAE AMS2175 - Casting, Classification and Inspection of
SAE AMS2423 - Plating, Nickel, Hard Deposit
SAE AMS2424 - Plating, Nickel Low-stressed Deposit
SAE AMS2430 - Shot Peening, Automatic
SAE AMS2700 - Steels, Passivation of Corrosion Resistant
SAE AMS3265 - Sealing Compound, Polysulfide (T) Rubber, Fuel Resistant,
Nonchromated Corrosion Inhibiting for Intermittent Use to
360 °F (182 °C)
SAE AMS3269 - Sealing Compound, Polysulfide (T) Synthetic Rubber for
Integral Fuel Tank and Fuel Cell Cavities High Strength, for
Intermittent Use to 360 °F (182 °C) (Stabilized Type)
SAE AMS3276 - Sealing Compound, Integral Fuel Tanks and General
Purpose, Intermittent Use To 360 °F (182 °C)
SAE AMS3277 - Sealing Compound, Polythioether Rubber, Fast Curing for
Integral Fuel Tanks and General Purpose, Intermittent Use to
360 °F (182 °C)
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MIL-STD-1568D
SAE AMS3278 - Sealing and Coating Compound: Polyurethane (PUR) Fuel

Resistant High Tensile Strength/Elongation For Integral Fuel
Tanks/Fuel Cavities/General Purpose
SAE AMS3279 - Sealing Compound, Sprayable For Integral Fuel Tanks and
Fuel Cell Cavities, For Intermittent Use to 350 °F (177 °C)
(Stabilized Type)
SAE AMS3281 - Sealing Compound, Polysulfide (T) Synthetic Rubber
for Integral Fuel Tank and Fuel Cell Cavities
Low Density for Intermittent Use to 360 °F (182 °C)
SAE AMS3284 - Sealing Compound, Low Adhesion, for Removable Panels
and Fuel Tank Inspection Plates
SAE AMS3374 - Sealing Compound, Aircraft Firewall, Silicone
SAE AMS4890 - Copper-Beryllium Alloy Castings 97Cu - 2.1Be - 0.52Co -
0.28Si Solution Heat Treated (TB00)
SAE AMS6532 - Steel, Bars and Forgings 3.1Cr - 11.5Ni - 13.5Co - 1.2Mo
(0.21 - 0.25C) Vacuum Melted, Normalized and Overaged
Precipitation Hardenable
SAE AMS7259 - Rubber: Fluorocarbon (FKM), High Temperature/Fluid
Resistant, Low Compression Set/ 85 to 95 Hardness,
For Seals In Fuel Systems and Specific Engine Oil Systems
SAE AMS7276 - Rubber: Fluorocarbon (FKM) High-Temperature-Fluid
Resistant Low Compression Set For Seals In Fuel Systems
and Specific Engine Oil Systems
SAE AMS7287 - Fluorocarbon Elastomer (FKM) High Temperature/HTS Oil
Resistant / Fuel Resistant Low Compression Set/70 to 80
Hardness, Low Temperature Tg -22 °F (-30 °C) For Seals in
Oil/Fuel/Specific Hydraulic Systems
SAE AMS7379 - Rubber: Fluorocarbon Elastomer (FKM) 70 to 80 Hardness,
Low Temperature Sealing Tg -40 °F (-40 °C) For
Elastomeric Seals in Aircraft Engine Oil, Fuel and
Hydraulics Systems
SAE AMS-C-8837 - Coating, Cadmium (Vacuum Deposited)
SAE AMS-C-83231 - Coatings, Polyurethane, Rain Erosion Resistant for Exterior
Aircraft and Missile Plastic Parts
SAE AMS-S-8802 - Sealing Compound, Temperature Resistant, Integral Fuel
Tanks and Fuel Cell Cavities, High Adhesion
SAE ARP4118 - Isolation and Corrosion Protection of Dissimilar Materials
SAE AS50881 - Wiring, Aerospace Vehicle
SAE AS81550 - Insulating Compound, Electrical, Embedding, Reversion
Resistant Silicone
SAE J2277 - Surface Vehicle Recommended Practice for Shot Peening
Coverage Determination
(Copies of these documents are available online at http://www.sae.org.)
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MIL-STD-1568D
AMERICAN WELDING SOCIETY (AWS)
AWS D17.1/D17.1M - Fusion Welding for Aerospace Applications
(Copies of this document are available online at http://aws.org.)
2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a
conflict between the text of this document and the references cited herein, the text of this
document takes precedence. Nothing in this document, however, supersedes applicable laws and
regulations unless a specific exemption has been obtained.
3. DEFINITIONS
3.1 Aerospace weapons systems. Applicable systems include fixed wing aircraft, unmanned
aerial vehicles, space vehicles, rotorcraft, missile systems, air delivered guided munitions, and all
related ground support equipment.
3.2 Aircraft structure. The structure of an aircraft includes the fuselage, wing, empennage,
landing gear, rotorcraft rotor and drive systems, propellers, control systems and surfaces,
airframe-engine interface components (including engine mounts, nacelles, air induction
components), weapon mounts, structural operating mechanisms, components that perform a
structural function, and other components as described in the contract specification.
3.3 Alternate manufacturing processes. Alternate manufacturing processes include, but are
not limited to, laser additive manufacturing, electron beam additive manufacturing, weldments
and cold spray processes to produce built-up structures.
3.4 Cognizant Engineering Authority (CEA). For the purpose of this standard, Cognizant
Engineering Authority is that entity from the procuring activity that reviews and approves any
deviations from the technical requirements contained within this standard.
3.5 Corrosion. The deterioration of a material or its properties due to a reaction of that
material with its chemical environment. Traditionally, corrosion was thought of only as
deterioration of metal (e.g., rusting of steel), but now corrosion includes degradation of non-
metallic materials. Some non-traditional examples include rotting of wood, degradation of
concrete (carbonation, alkali-silica reaction phenomena), and degradation of composite materials
due to reaction with the environment.
3.6 Corrosion Prevention and Control (CPC). The rigorous application of engineering,
design and analysis, quality assurance, nondestructive inspection, manufacturing, operations, and
support technologies to:
a. prevent the start of corrosion

b. minimize functional impairment from corrosion, and
c. define processes for the tracking and repair of corrosion problems.
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MIL-STD-1568D
3.7 Corrosion Prevention and Control Plan (CPCP). This plan describes the specific
corrosion prevention and control measures to be implemented for the purpose of minimizing
corrosion throughout the acquisition lifecycle, as well as a plan for establishing a CPCP timeline
(see Appendix A) and a Corrosion Prevention Team (see Appendix B).
3.8 Corrosion prevention and control planning. Consists of planning and establishing:
a. a management structure for CPC, and
b. the technical considerations and requirements in order to implement an effective CPC
regime throughout the life cycle of a program. CPC planning must include program
management, engineering (including systems engineering), life cycle logistics, test and
evaluation, budget/funding and contracting. A CPC Plan (CPCP) formally documents the CPC
planning and execution, and is updated, refined and matured as the program proceeds through the
life cycle phases.
3.9 Corrosion Prevention Team (CPT). A team that consists of Government and contractor
personnel within each aerospace weapons system management function with the purpose of
focusing on and emphasizing Corrosion Prevention and Control (CPC) planning and execution
throughout the life of the program. Examples include a Corrosion Prevention Advisory Board
(CPAB), Corrosion Action Teams (CAT), etc.
3.10 Critical surface/part. A surface/part on an aerospace weapons system that has been
identified through analysis, test, or service history as being especially sensitive to the presence of
damage.
3.11 Damage. The presence of any crack, flaw, corrosion, disbond, delamination, and/or
other feature that degrades, or has the potential to degrade, the performance of the affected
component.
3.12 Durability. The ability of the structure and/or components to resist cracking, corrosion,
thermal degradation, delamination, wear and the effects of foreign object damage for a
prescribed period of time.
3.13 Erosion. The progressive loss of material from a surface due to impinging fluid or
solid particles.
3.14 Exterior surfaces. All surfaces normally exposed to an external environment are
considered exterior surfaces. All interior surfaces that may also become wetted with water or
corrosive fluid are considered exterior surfaces. These surfaces include, but are not limited to,
wheels and landing gear, wheel wells, and their fairings, control surfaces, wing-fold areas,
battery compartments, and bilge areas on aircraft with latrines.
3.15 Microbially Influenced Corrosion (MIC). Corrosion that is caused or promoted by

microorganisms such as bacteria or fungus. It can apply to both metals and non-metals.
3.16 Nondestructive Inspection (NDI). The inspection of a structure or component in any

manner that will not impair its future usefulness. The purpose of NDI may be to detect flaws at
or beneath the external surface of a part, measure geometric characteristics, determine material
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MIL-STD-1568D
structure or composition, or it may characterize physical, electrical, or thermal properties without

causing changes in the part.
3.17 Stress Corrosion Cracking (SCC). Cracking induced from the combined influences of
sustained tensile stress and a corrosive environment.
3.18 Structural integrity. The condition that exists when a structure is sound and unimpaired
in providing the desired level of structural safety, performance, durability, and supportability.
3.19 Supportability. Acceptable quality and cost-effective preventive methods and/or in-
service repair methods are either available or can be developed in a timely manner to mitigate the
deterioration of materials and structures fabricated using the selected manufacturing processes
and joining methods.
3.20 Sustainment. Sustainment involves the supportability of fielded systems and their
subsequent life cycle product support – from initial procurement to supply management
(including maintenance) to reutilization and disposal. It can include functions such as initial
provisioning, cataloging, inventory management and warehousing, and depot and field level
maintenance.
3.21 Wear. Damage at an interface, generally with progressive loss of material from one or
both surfaces, due to relative motion between the surfaces. Wear mechanism includes adhesive,
abrasive, and fretting wear, as well as corrosive and thermal wear.
4. GENERAL REQUIREMENTS
4.1 Corrosion Prevention and Control Plan (CPCP). The CPCP addresses the design,
materials, and processes intended to be used on the specific system being procured including
system interfaces, installation of government furnished equipment, and commercial items
procured off-the-shelf. The CPCP shall contain the following (see 6.2b):
a. System design, engineering and manufacturing requirements, operations, logistics, and

sustainment phases that mitigate corrosion and are consistent throughout system life.
b. An integrated management structure that ensures ongoing, effective CPC communication
and coordination among team members by defining roles and responsibilities for quality
assurance, process control, materials/process engineering, manufacturing, low
observables, technical writing, and Environment, Safety, and Occupational Health
(ESOH) compliance.
c. Materials, processing methods, manufacturing techniques, fabricating processes and
protective treatments identified in the finish specification.
d. Methods for CPC sustainability, logistics support, maintenance planning (such as
methods/equipment for corrosion monitoring and non-destructive inspection), ground
support and test equipment, handling, transportation, and storage of parts/assemblies,
personnel training and the generation/validation/verification of technical information.
e. Performance verification methods for full stack-ups of the overall protective schemes,
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MIL-STD-1568D
including low observable materials.

f. Methods to achieve compromises between conflicting requirements of corrosion
mitigation, low observables, electrical grounding, environmental compliance, safety and
occupational health. Life Cycle Costs shall be a factor in achieving said compromises.
g. An interface with suppliers, subcontractors, sub-systems manufacturers and the
procurement of commercial-off-the-shelf items that validates, verifies, and ensures
compliance to the plan and finish specification.
h. References to applicable specifications and standards.
4.2 Finish specification. The finish specification shall be in accordance with MIL-STD-7179
and identifies the specific materials, processing methods, manufacturing techniques, protective
pretreatments and treatments, organic and inorganic coatings, seals and sealants to be used for
protection against corrosion of the assemblies, sub-systems and components selected for the
specific system being procured and which have been identified in the corrosion prevention and
control plan. All finishing materials and processes shall conform to applicable Federal and State
regulations. All signature control and miscellaneous functional coating/finishing materials shall
be included in and comply with the finish specification (see 6.2c).
4.3 Sustainment. Since corrosion prevention, control, and mitigation contribute

significantly to the total cost of aerospace weapons systems ownership, the requirements of this
standard shall be met during upgrades, procurement of spare parts, major repairs, modifications
and similar support phases of existing systems. Department of Defense Directive (DoDD)
5000.01 recognizes that corrosion prevention and control is an issue over the life of an
aerospace weapons system and emphasizes (1) the best time to off-set the effects of corrosion
is early in system development, and (2) the requirements for the best design and
materials/processes/finish selections need to prevail during the operational and support phases of
fielded aerospace weapons systems. Any procurement of spare parts, upgrades, repairs and other
sustainment initiatives exceeding five million dollars shall require a corrosion control plan and
an accompanying process/finish specification, according to the Defense Federal Acquisition
Regulation Supplement (DFARS) Part 207.105. The intent is to ensure coordination and
implementation of the original corrosion prevention and control plan and process/finish
specification that were approved during acquisition be continued throughout system life.
Elements of a sustainment corrosion program can be found in the “Corrosion Prevention and
Control Planning Guidebook for Military Systems and Equipment.”
4.4 Materials and process considerations in design.
4.4.1 Selection considerations. The primary consideration in the design and construction of
aerospace weapons systems is the ability of the design to comply with structural and operational
requirements. In addition, the aerospace weapons systems are expected to perform reliably and
require minimum maintenance over a specified lifetime, which includes minimizing the rate of
deterioration. Therefore, in the selection of materials and processing methods to satisfy system
requirements, consideration shall also be given to those materials, processing methods and
protective treatments which reduce failures due to deterioration. Modeling and validation testing
shall be performed to identify corrosion-prone locations. Testing shall include selected materials,
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MIL-STD-1568D
assembly techniques, and corrosion protection schemes in relevant environments and in-service
loadings.
4.4.2 Guided missiles and rocket systems. Since guided missiles, rockets, and
their components have low maintenance and high reliability performance requirements,
MIL-STD-186 in conjunction with MIL-STD-1568 shall be used to establish materials and
process requirements to protect these weapons systems from deterioration ensuring they meet
their intended useful life.
4.4.3 Alternate manufacturing processes. Components produced using alternate

manufacturing processes shall meet or exceed the CPC design capabilities of traditionally
manufactured components.
4.5 General design requirements for corrosion prevention.
4.5.1 Exclusion of rain and airborne spray. The design of the system shall prevent water
intrusion into, or being driven into, any part of the system interior or sealed components. All
windows, doors, panels, canopies, etc. shall be provided with sealing arrangements that prevent
entry of water when these items are correctly closed. Wetting of equipment, thermal insulation,
and sound proofing materials shall be prevented. Recesses shall be avoided so that moisture and
solid matter cannot accumulate to initiate localized attack. Sealed floors shall be provided for
galleys, toilets, and crew compartments.
4.5.2 Ventilation. Ventilation to minimize moisture retention and buildup shall be included
in the system design considerations and validated during system design testing.
4.5.3 Drainage. Drain holes shall be provided to prevent collection or entrapment of water
or other unwanted fluid in areas where exclusion is impractical. Unless otherwise approved by
the procuring activity, the minimum diameter for all drains shall be 0.375 inch (9.525 mm). All
designs shall include considerations for the prevention of water or fluid entrapment and ensure
that drain holes are located to permit maximum drainage of accumulated fluids. Actual system
configuration and attitude, in flight and on the ground, shall be considered in addition to
component design. Drainage shall be provided for crew compartments, avionics bays and boxes,
engine bays/nacelles in such a manner that nearby structure shall not be compromised.
4.5.4 Galvanically dissimilar materials. Use of dissimilar metals in contact, as specified in

MIL-STD-889, shall be limited to applications where similar metals cannot be used due to
design requirements. When it is necessary to use dissimilar metals in contact, the metals shall be
protected against galvanic corrosion. Composite materials containing graphite fibers shall be
treated as graphite in MIL-STD-889 and treated in accordance with the methods and guidelines
of SAE ARP4118, where applicable.
4.5.5 Insulation/acoustic blankets. When required, insulation/acoustic blankets shall be

procured with a permanent, baked-on water repellent binder system or protected with sealant to
prevent any moisture from being absorbed by the blanket. Blankets shall be attached to the
system frame members in a stand-off fashion to avoid contact with vehicle skins. This distance
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MIL-STD-1568D
shall be sufficient to prevent moisture entrapment against the skins and to allow for drainage of
fluids. Such attachment shall permit the blankets to be easily removed and re-attached to
facilitate maintenance and inspection. Specific requirements shall be provided by the Cognizant
Engineering Authority.
4.5.6 Nondestructive inspection (NDI) for corrosion. For corrosion prone areas requiring
inspection, access for inspection throughout the system lifecycle shall be evaluated during
system design in order to identify inspectable and non-inspectable areas. Areas deemed non-
inspectable may require additional corrosion control and prevention measures in order to
mitigate the risk of not being able to inspect periodically. The selection of coating and corrosion
removal processes requires consideration of their effects on NDI methods. When industry
standard NDI methods cannot be utilized, alternate NDI methods may be utilized with the
permission of the Cognizant Engineering Authority.
4.5.6.1 NDI methodologies and techniques. NDI methodologies and techniques shall be
considered during the design and procurement of aerospace weapons systems. NDI
methodologies and techniques shall be required for aerospace weapons systems when the design
activity or system specifications require NDI (see 6.2d) for product acceptance and recurring
inspection for long-term sustainment. NDI requirements shall be established and adhered to
during system development, test, production, and sustainment through the life cycle of the
weapons system. MIL-HDBK-6870 can be used to determine key elements of NDI, which
include the following:
a. Parts classification.
b. Coordination of design requirements and production NDI procedures.
c. Preparation and approval of production NDI procedures.
d. Development of NDI methods and procedures to support test articles.
e. Coordination, documentation of inspection requirements and procedures to support
long-term sustainment including structural repairs.
f. Validation and verification of inspection procedures to support long-term
sustainment.
g. Assessment and documentation of sustainment NDI capability.
h. Qualification of new technologies for use during production or component/aircraft
testing or during the service life of the system.
i. Qualification of NDI methods adapted for the purpose of in-situ structural damage
sensing.
j. Consideration for surface finish and preparation, prior to fluorescent penetrant
inspection.
4.6 Metallic materials.
4.6.1 Aluminum.
4.6.1.1 Alloy selection. The selection of aluminum alloys for structural applications
requires consideration of their resistance to stress-corrosion cracking (SCC). Maximum use shall
be made of alloys and heat treatments that minimize susceptibility to SCC. Relative SCC ratings
for high-strength aluminum alloy products based on ASTM G64 and service experience are
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MIL-STD-1568D
provided in Table I. Although the ratings are based primarily on the results of standard corrosion
tests, such as ASTM G64, an experience factor may be substituted for those materials that have
established service records. The ratings are given for tests conducted in the Short Transverse
Grain Direction (STGD) on plate greater than 0.080 inch (2.032 mm) in thickness as this is the
most critical SCC condition. For welded assemblies, castings and parts made via metal additive
processes (powder, wire or foil), testing for SCC shall be performed in the final heat treat
condition. If no post production thermal treatment is applied, a sufficient amount of time (not
less than 2 weeks) shall be allowed for the material to stabilize. Thermally accelerated
stabilization treatments are allowed with the permission of the CEA. For alloys not included in
Table I, consult the CEA.
TABLE I. Rating for resistance to SCC aluminum alloys in the short transverse grain
direction (STGD).
Alloy and temper Rolled plate Rod and bar Extruded Forgings
shapes
2014-T6 Low Low Low Low
2024-T3, T4 Low Low Low Low
2024-T6 High Low
2024-T8 High Very high High Intermediate
2124-T851 High
2219-T351X, T37 Very high Very high Very high
2219-T6 Very high Very high Very high Very high
6061-T6 Very high Very high Very high Very high
7005-T53, T63 Low Low
7039-T64 Low Low
7049-T74 Very high High High
7049-T76 Intermediate
7149-T74 High High
7050-T74 High High High
7050-T76 Intermediate High Intermediate
7075-T6 Low Low Low Low
7075-T736 High
7075-T74 Very High Very High Very High Very High
7075-T76 Intermediate Intermediate
7175-T736 High
7475-T6 Low
7475-T73 Very High
7475-T76 Intermediate
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MIL-STD-1568D
4.6.1.2 Aluminum alloy selection limitations. Wrought product forms of aluminum alloys
2020, 7079, and 7178 in all temper conditions and 7075-T6 shall not be used for structural
applications. Use of 2000-series aluminum alloys in the -T3 and -T4 tempers and 7000-series
aluminum in the -T6 tempers in thicknesses greater than 0.080 inch (2.032 mm) shall not be
used. Suitably clad aluminum alloys or inherently corrosion-resistant alloys shall be used in
exterior skin that is 0.125 inch (3.175 mm) or less in thickness, forms a leading-edge, exhaust
trail area of any source or wheel well area, is spot- or seam-welded, or is the face sheet in
bonded sandwich construction. Non-clad materials may be used for the aileron skins, the flap
shroud skins and the flap shroud closure pocket. To preclude partial aging in heat-treatable
alloys, the bonded sheet shall be in the artificially aged condition prior to bonding. The
references to exterior surfaces and skin herein mean the external surface only and do not
preclude use of material clad only on one side or the removal of cladding from internal
surfaces.
4.6.1.3 Maximum metal removal. Metal removed from non-stress relieved structural parts
after final heat treatment shall not exceed 0.150 inch (3.81 mm) per side, unless the following
conditions are met. Final temper of condition has been demonstrated to have a stress-corrosion
resistance of 25 ksi (173 MPa) or higher in the short transverse grain direction as determined
by a 20-day alternate immersion test provided in ASTM G47 or equivalent as approved by the
CEA.
4.6.1.4 Clad aluminum sheet. All aluminum sheets used in external environments and
interior corrosive environments shall be clad on both sides except where the design requires
surface metal removal by machining, chemical milling, and adhesive bonding or where alloys of
the 1000, 3000, 5000, or 6000 series type are used. Clad high strength aluminum alloys shall not
be fusion welded.
4.6.1.5 Compressive residual surface stress for corrosion resistance and fatigue life
improvement. Compressive residual stress is applied via shot peening in accordance with SAE
AMS2430 or other methods approved by the CEA. Critical surfaces of all structural forgings,
machined plate and extrusions, where accessible after final machining and heat treatment, shall
be shot peened in accordance with SAE AMS2430 and SAE J2277 or other methods approved
by the CEA. Exceptions are alloys having a demonstrated stress corrosion resistance of 25 ksi
(173 MPa) or higher in the short transverse direction, and web areas under 0.080 inch (2.032
mm) thick where no short transverse grain is exposed by machining. Those areas of forgings
requiring lapped, honed, or polished surface finishes for functional engineering requirements
shall be shot peened prior to these surface finish operations. All aluminum products with an
ASTM G47 stress corrosion threshold less than 25 ksi (173 MPa) shall, after shot peening, have
essentially no residual surface tensile stresses in the final heat treated and machined condition.
Attachment points for primary structure shall be shot peened for improved fatigue resistance.
Finish clean-up of shot peened surfaces as required for fit up shall not exceed 0.003 inch (0.076
mm) of surface removal for aluminum alloys. Holes in primary structure shall be cold worked
using processes approved by the CEA. Mechanical removal of material or exposure to
temperatures exceeding 180 °F (82 °C) requires reapplication of the compressive surface layer
processes.
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MIL-STD-1568D
4.6.1.6 Stress corrosion factor. Practices, such as the use of press or shrink fits, taper pins,
clevis joints in which tightening of the bolt imposes a bending load on the female lugs, and
straightening or assembly operations, which result in sustained or residual surface tensile stress
shall be avoided. In cases where such practices cannot be avoided, corrective practices, such as
stress relief heat treatment and optimum grain flow orientation shall be used to minimize the
hazard of stress corrosion cracking. Materials selection shall consider the increased residual
tensile stress (increased potential for SCC) due to out of tolerance conditions of non-conforming
parts.
4.6.1.7 Aluminum lithium (Al-Li) alloys (special considerations). Al-Li alloys shall only be
used with permission from the CEA.
4.6.2 Steels.
4.6.2.1 Low alloy, high strength steels. All low alloy, high strength steel parts, 180 ksi
(1241 MPa) ultimate tensile strength (UTS) and above, including fasteners, require corrosion
preventative coatings by a process proven to be non-embrittling, to the requirements of
ASTM F519 for the alloy/heat treatment combination. Any corrosion resistant plating used on
steels above 180 ksi (1241 MPa) UTS shall exhibit a re-embrittlement resistance of more than
200 hours in the standard ASTM F519 testing using the 1A specimen. Selection of steels shall be
as follows:
a. Aircraft-quality, vacuum-melted steel shall be used for parts which are heat treated to an
ultimate tensile strength of 220 ksi (1516 MPa) and above.
b. The maximum ultimate tensile strength in production parts shall not be greater than
20 ksi (137 MPa) above the established allowable minimum requirement.
c. Compositions shall be selected such that heat treatment to the required strength and
service temperatures shall preclude temper embrittlement, blue brittleness, or brittle
temper.
d. Steels shall be selected to have ductile-brittle fracture transition temperatures as

determined by impact test, below the minimum operating temperature.
e. Steels whose mechanical properties are developed by cold deformation shall have the
recovery temperature of at least 50 ºF (10 ºC) above the expected operating temperature
range.
f. Critical parts shall be designed and processed so as to result in no decarburization in

excess of 0.003 inch (0.076mm) of highly stressed areas. Elsewhere, decarburization
shall be avoided and, where unavoidable, shall be compensated by appropriate reduction
in design fatigue strength. Unless otherwise specified, designs shall preclude use of as-
forged surfaces. Carburization and partial decarburization of fully hardened steel parts
shall be restricted such that the difference in hardness from the surface to the nominal
subsurface hardness shall not exceed two hardness units Rockwell C (HRC).
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MIL-STD-1568D
g. The mechanical drilling of holes in martensitic steels after hardening to strength levels of
180 ksi (1241 MPa) and above shall be avoided. When such drilling is unavoidable,
processes shall be in accordance with the procuring activity approved material and
process specifications.
h. Grinding of martensitic steels and chromium plated martensitic steels hardened to 200 ksi
(1378 MPa) and above shall be in accordance with MIL-STD-866.
i. Aeromet 100 shall be procured in accordance with SAE AMS6532.
j. H-11, D6-AC, 4340M and 300M steels shall not be used.
4.6.2.2 Stress corrosion factors. Press or shrink fits, taper pins, clevis joints in which
tightening of the bolt imposes a bending load on the female lugs, and straightening or assembly
operations that result in sustained residual surface tensile stresses shall be avoided for alloy steel
parts heat treated to 180 ksi (1241 MPa) UTS and above. In cases where such practices cannot
be avoided, protective treatments, such as stress relief heat treatments, optimum grain-flow
orientation, wet installed (with a protective material) inserts and pins, and shot peening or similar
surface working to minimize the hazard of SCC or hydrogen embrittlement damage, shall be
applied. Only the following corrosion resistant and high strength steel shall be used for critical
parts: HP 9-4-30, PH 13-8, AF-1410, Modified AF-1410, and AERMET 100. For steel
weldments the SCC resistance shall be prepared and inspected in accordance with ASTM G58.
4.6.2.3 Corrosion resistant steels (CRES). CRES shall be considered for all applications to
reduce/eliminate the use of environmentally unfriendly/hazardous surface treatments. All CRES
shall be passivated in accordance with SAE AMS2700 or ASTM A380/A380M or equivalent as
approved by the CEA. While both SAE AMS 2700 and ASTM A380/A380M permit the use of
citric acid for passivation, use of this process shall be approved by the CEA. In addition,
martensitic steels require coatings for protection against corrosion. Table II provides corrosion
information for CRES.
4.6.2.3.1 Corrosion resistant steel limitations. Precipitation hardened steels shall be aged at
temperatures not less than 1000 ºF (538 ºC). Exceptions are those alloys that exhibit acceptable
SCC resistance when tested in accordance with ASTM G58; castings that are aged at 935 ±15 ºF
(501.5 ±9.4 ºC); fasteners in the H950 condition, and springs that have optimum properties at the
CH 900 condition. Corrosion resistant maraging steels shall not be used in sustained load
applications and if used (e.g., ALMAR 362, CUSTOM 455, CUSTOM 450) shall be aged at
temperature not less than 1000 ºF (538 ºC). Corrosion resistant 19-9DL and 431 steels shall not
be used for any applications. Series 400 martensitic grade corrosion resistant steels shall not be
used in the 700 ºF to 1100 ºF (371 ºC to 593 ºC) tempered condition 150 to 180 ksi (1034 to
1241 MPa strength ranges). Unstabilized austenitic steels shall not be fusion welded.
Precipitation hardening semi-austenitic grades shall not be used in applications that require
extended exposure to temperatures in the 750 ºF through 900 ºF (398 ºC through 482 ºC) range.
Only stabilized austenitic steels (321 and 347) are to be used above 698 ºF (370 ºC). Free
machining stainless steels shall be avoided for all applications. All welded or brazed austenitic
steel shall be solution heat treated after welding; however, welded 321 and 347, 304L, and 316L
may be used without post weld solution heat treatment.
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MIL-STD-1568D
4.6.2.4 Titanium.
4.6.2.4.1 Surface considerations. The surfaces of titanium products (sheet, plate, bar,
forging, casting, metal additive, and extrusion) shall be 100 percent machined, chemically
milled, or pickled to remove all contaminated zones and layers formed while the material was at
elevated temperature. This includes contamination as a result of mill processing, heat treating
and elevated temperature forming operations and welding. Chemical cleaning shall be performed
in accordance with ASTM B600 or equivalent as approved by the CEA. Adequate removal of
detrimental layers shall be confirmed through the use of inspection techniques approved by the
CEA.
4.6.2.4.2 Fretting. Titanium alloys are highly susceptible to reduction in component life by
fretting at interfaces between titanium alloys or titanium and other metals. In any design where
fretting is suspected, tests shall be conducted to determine whether such a condition will exist
and ensure that component life requirements are met. Design considerations shall be applied to
minimize fretting in structural applications including provision made for anti-fretting coatings or
inserts. The effect of anti-galling/anti-fretting compounds on the corrosion performance of the
joint shall be determined.
TABLE II. Corrosion characteristics of corrosion resistant steels.
General Corrosion Stress corrosion

Class Alloy Resistance Resistance
301 High Very high
302 High Very high
304 High Very high
Austenitic 310 High Very high
316 Very high Very high
321 High Very high
347 High Very high
440C Low to moderate - will Susceptibility varies
420 develop superficial rust significantly with
Martensitic film with atmospheric composition, heat treatment
410
exposure and product form
416
21-6-9 Moderate
13-8Mo Moderate
15-7Mo Moderate Susceptibility varies
14-8Mo Moderate significantly with
17-4PH Moderate composition, heat treatment,
Precipitation
15-5PH Moderate and product form.
Hardening
AM355 Moderate
AM350 Moderate
9Ni 4Co-0.20C Moderate Very high
9Ni 4Co-0.30C Moderate Very high
9Ni 4Co-0.45C Moderate Low
Other A286 High Very high
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MIL-STD-1568D
4.6.2.4.3 Special precautions. Titanium parts and fasteners shall not be plated with
cadmium, zinc, or silver. Cadmium, zinc, or silver plated hardware clamps, tools, fixtures, and
jibs shall not be used for fabrication or assembly of titanium components or structures.
Cadmium, zinc or silver plated parts, such as press fit bushings and fasteners, shall not be used in
contact with titanium components.
4.6.2.4.4 Titanium contamination. Care shall be taken to ensure that cleaning fluids and other
chemicals are not used on titanium assemblies where entrapment can occur. Substances that are
known to be contaminants and produce SCC include, but are not limited to, hydrochloric acid,
trichloroethylene/trichloroethane, carbon tetrachloride, all chlorides, chlorinated cutting oil,
halogenated hydrocarbons, and methyl alcohol.
4.6.2.5 Magnesium. Magnesium alloys shall not be used.
4.6.2.6 Beryllium and aluminum-beryllium alloys. All beryllium and beryllium containing
alloys shall be used in a passivated condition by a process approved by the CEA. High content
beryllium alloys (>2 percent Be) shall not be used. Alloy UNS C17200 or UNS C17300 or
equivalent is required. Wrought beryllium copper shall be acquired in accordance with ASTM
B196/B196M, ASTM B197/B197M, or ASTM B194. Beryllium copper castings shall be
acquired in accordance with SAE AMS4890 and classified (class and grade) in accordance with
SAE AMS2175.
4.6.2.7 Mercury. Mercury shall not be used where spillage can contact brass, aluminum and
titanium alloys.
4.6.2.8 Depleted uranium. Depleted uranium shall not be used without the specific
approval of the CEA. If approved for use, the general finish for depleted uranium shall be
nickel plated in accordance with SAE AMS-QQ-N-290 or aluminum coated in accordance with
MIL-DTL-83488, plus one coat of MIL-PRF-23377, Type I primer, thickness 0.0006 to 0.0009
inch (0.015 to 0.023 mm).
4.6.2.9 Tin and tin alloys. If tin or tin alloys are used where the possibility of tin pest
occurrence is expected, mitigation strategies shall be addressed in the CPCP.
4.6.2.10 Bronze bearing alloys. The use of bronze alloys is prohibited, except for
wrought UNS C63000 aluminum-nickel bronze in accordance with ASTM B150/B150M,
ASTM B169/B169M used in moderate and light duty bearing load applications, and aluminum
bronze (alloys UNS C95200-C95800) casting classified (class and grade) in accordance with
SAE AMS2175, and acquired in accordance with ASTM B30, ASTM B66, ASTM B148, ASTM
B271/B271M, ASTM B505/B505M, ASTM B763/B763M, and ASTM B806.
4.6.3 Organic materials. The following restriction shall apply to the selection of elastomers,
plastics, and other organic materials used in the fabrication of aerospace structures and
components:
a. All organic materials shall have resistance to degradation and aging (including
resistance to hydrolysis, ozonolysis and other chemical processes exacerbated by
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MIL-STD-1568D
atmospheric or operational exposure), and minimum flammability consistent with

performance requirements for the intended use.
b. Hazardous decomposition and other out gassing products that are volatile and
leachable, released by organic materials under operating conditions shall not come in
contact with materials components or personnel.
c. Cellular plastics, foams and wood shall not be used for skin stabilization in structural
components, other than in all-plastic sandwich components. Use of foam as sandwich
core material shall not be used.
d. Natural leather degrades quickly and shall not be used.
e. Elastomeric encapsulating compounds used shall conform to MIL-PRF-8516,
MIL-PRF-23586, MIL-M-24041, MIL-A-46146, or SAE AS81550. Use of
hydrolytically unstable encapsulation materials is prohibited.
4.6.4 Composites. Imide-based/graphite composites shall not be used in structures not
accessible for non-destructive inspection, non-inspectable structure, or non-removable by
organizational level maintenance. Imide-based or graphite composites shall not be in contact
with or adjacent to parts/materials that are susceptible to corrosion (aluminum, steel, tin)
including, brackets, clips, gang channels, tubing, fasteners, etc.
4.6.5 Corrosion prevention during manufacturing operations and storage. Precautions shall
be taken during manufacturing operations and long-term storage of materials and commodities to
prevent the introduction of corrosion or corrosive elements. (See 4.6.9.)
4.6.6 Cleaning. Cleaning of various types of metallic surfaces, prior to application of the
surface treatments and coatings, shall be as specified in MIL-DTL-5002 and in accordance with
TT-C-490, using materials and processes that have no damaging effect on the metal, including
freedom from pits, intergranular attack and significant etching. After cleaning, all parts shall be
completely free of corrosion products, scale, paint, grease, oil, flux, and other foreign materials,
including other metals, and shall be given the necessary treatment immediately after cleaning.
Particular care shall be exercised in the handling of parts to ensure that foreign metals are not
inadvertently transferred, as may occur when steel is allowed to come into contact with zinc
surfaces and cadmium in contact with titanium. All closed compartments shall be cleaned prior
to closeout assembly to remove debris such as metal chips, broken fasteners, dust, and other
foreign material. Particular attention shall be given to ensure that drain holes are not blocked.
4.6.7 Surface damage. Damage to surface treatments or protective finishes shall be repaired
prior to component assembly, including faying surfaces. Inorganic and organic coatings used for
repair shall be the same as those on the undamaged areas. Application of coatings shall be in
accordance with MIL-DTL-18264 using approved material specifications and qualified
materials.
4.6.8 Marking pencils. Graphite containing marking devices (e.g. lead pencils, etc.) shall
not be used to mark metal parts.
4.6.9 Protection of parts during storage and shipment. All parts and assemblies shall be
given adequate protection to prevent corrosion and physical damage during storage and
shipment. Packaging practices shall conform to MIL-STD-2073-1.
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MIL-STD-1568D
4.6.9.1 Storage and shipping preservatives. MIL-PRF-46170 shall not be used as a rust
inhibiting storage fluid. While MIL-PRF-46170 may prevent rust, it will deposit a barium
containing compound onto metallic surfaces leading to potential component (e.g., valves)
failures. Operational fluids, such as MIL-PRF-83282 and MIL-PRF-87257, shall be used to fill
components instead of using MIL-PRF-46170. MIL-PRF-81322 shall not be used as a shipping
preservative. MIL-PRF-32014 should be used in place of MIL-PRF-81322 as a shipping
preservative with few exceptions (see 4.6.14.2).
4.6.10 Inorganic finishes. Cleaning, surface treatments, and inorganic finishes for metallic
surfaces of aerospace weapons systems shall be in accordance with MIL-DTL-5002. Those
surfaces or parts located in corrosion susceptible areas that form exterior surfaces of the system,
shall require chemical finishing to provide maximum corrosion resistance in accordance with life
cycle cost considerations. Emerging environmentally compliant inorganic finishes shall be
approved by the CEA. Approval for new finishes shall be based upon detailed test plans that are
formulated and executed to subsequently demonstrate equivalency (or better) to the inorganic
finish being replaced.
4.6.10.1 Cadmium coatings. High strength steels having an ultimate tensile strength of
180 ksi (1241 MPa) and above, shall be plated in accordance with MIL-STD-1500, with the
vacuum deposition process in accordance with SAE AMS-C-8837, or electrodeposited in
accordance with SAE AMS-QQ-P-416, Type II, Class 2. Cadmium-plated fasteners used in
areas where contact with fuel can occur, shall be over coated with an approved fuel tank
sealant in accordance with 4.6.12.
4.6.10.2 Aluminum coatings. Aluminum coatings in accordance with MIL-DTL-83488 or

equivalent are an acceptable alternative to cadmium with the approval of the CEA. Ion Vapor
Deposited (IVD) aluminum coatings shall be peened to eliminate porosity where galvanic
dissimilarities are adverse to the material being coated. IVD aluminum coatings shall not be used
where dissimilarity with the base material results in corrosion pitting if there is damage or
porosity. Cold spray aluminum may be used in accordance with MIL-STD-3021 for non-
structural and non-outer-mold line applications with permission of the CEA as an acceptable
alternative to cadmium.
4.6.10.3 Nickel plating. Aluminum structures, avionics boxes, components or connectors

shall not be nickel plated.
4.6.10.3.1 Undercoating. Where the selected coating does not provide corrosion protection
for the base metal and the coated surface or portion thereof is exposed to corrosive
environment, an undercoat of 0.0010 to 0.0016 inch (0.0254 mm to 0.040 mm) of nickel on
steel or zinc parts or an undercoat of 0.0008 to 0.0010 inch (0.020 mm to 0.0254 mm) of nickel
on copper alloy parts in accordance with SAE AMS2423 or SAE AMS2424 shall be used.
Coatings proposed for applications where temperatures exceed 1000 oF (538 oC) in service
shall be subject to approval of the CEA.
4.6.10.4 Zinc plating. Zinc or zinc-containing platings and coatings shall not be used on
alloy steel parts heat treated to 160 ksi (1103 MPa) UTS without CEA approval.
20
MIL-STD-1568D
4.6.10.5 Chromium plating. Chromium plating shall be considered acceptable corrosion

prevention for alloy steel wear surfaces only when the chrome plating is periodically lubricated
(fluid or grease types only) or a pure copper flash followed by a 0.0015 inch (0.038 mm)
minimum layer of nickel plating is applied under the chromium. All chromium plated steel parts
shall be shot peened prior to plating. Chromium plated surfaces shall not be used in applications
where service temperatures exceed 700 ºF (371 ºC).
4.6.11 Organic finishes. All organic finishes and coatings shall be in accordance with
MIL-STD-7179.
4.6.11.1 Organic finishes and systems (for Air Force systems). For Air Force systems, all
exterior paints and colors shall be consistent with thermal design requirements and shall conform
to MIL-PRF-85285, Type IV aliphatic polyurethane topcoat over MIL-PRF-23377, Type I or II,
Class C1 or C2 or MIL-PRF-85582, Type I or II, Class C1 or C2 primer. Class N of these
two primers may be used on the outer-mold-line only, with the approval of the CEA. As an
alternative to the aforementioned finish systems, i.e. MIL-PRF-23377, MIL-PRF-85582,
and MIL-PRF-85285, materials qualified to MIL-PRF-32239 are acceptable. Exterior surfaces
subjected during service to high stress, structural flexing, or susceptible to extreme corrosive
attack shall be primed with MIL-PRF-81733, Type III, or TT-P-2760 followed by
MIL-PRF-85285, Type IV topcoat. In high temperature areas, the selected material shall be
approved by the CEA. Those nonmetallic components coated for erosion resistance with
SAE AMS-C-83231, Class A or B and which may be chemically stripped during sustainment
shall have a wash primer base coat, applied prior to application of the Class A or B polyurethane
coats.
4.6.11.2 Fire insulating paint. Within power-plant compartments of aircraft and other
compartments normally operating at temperatures below 300 °F (149 °C), where fires are
likely to occur as a result of flammable fluid leakage, and in areas adjacent to bleed air
ducts and valves that contain air at temperatures above 300 °F (149 °C), all fluid containers
(air bottles, oxygen containers, hydraulic reservoirs, accumulators, and cylinders) that could
escalate the intensity of a fire by explosion due to excessive heat, shall be protected by a finish
system. The finish system shall consist of a primer qualified and applied in accordance with
MIL-PRF-23377 or MIL-PRF-85582 and a thermally insulating fire barrier topcoat and
sealants (such as SAE AMS3374), as determined by the CEA.
4.6.12 Environmental sealing. All permanent joints and seams located in exterior or internal
corrosive environments, including those in landing gear wells, control surface vents, attachment
wells and structure under fairings shall be faying surface sealed with sealants conforming to
MIL-PRF-81733, SAE AMS3265, SAE AMS-S-8802, SAE AMS3281, SAE AMS3276, and
SAE AMS3277. When operational temperatures are anticipated to exceed 225 ºF (107 ºC),
sealant conforming to SAE AMS3276 or SAE AMS3277 shall be used. For scaling areas that
operate at 275 ºF to 500 ºF (135 ºC to 260 ºC), sealant conforming to SAE AMS3374 shall be
used. Sealants used in integral fuel tanks shall conform to MIL-STD-7179 or SAE AMS3278,
SAE AMS3269, or SAE AMS3279. Removable panels and access doors shall be sealed, either
by rubber gaskets, molded seals, mechanical seals, or separable low-adhesion faying surface
sealants conforming to SAE AMS3284. High adhesion sealants such as those conforming to
21
MIL-STD-1568D
SAE AMS-S-8802, SAE AMS3277, SAE AMS3281, or SAE AMS3276 may be used for access
door sealing provided the proper parting agent is used on one surface. Alternative faying surface
products, such as non-curing sealants and gel tapes, shall be approved by the CEA.
4.6.13 Fastener installation. Fasteners shall be installed in accordance with MIL-STD-7179.
Waterborne primers, such as those in accordance with MIL-PRF-85582, shall not be used for
permanent fastener wet installation. Sealant or corrosion inhibiting coatings other than those
specified in MIL-STD-7179 shall not be used unless approval has been obtained from the CEA.
Quick release fasteners and removable fasteners penetrating exterior surfaces shall be designed
and installed so as to provide a seal to prevent moisture or fluids from entering. Holes for these
fasteners shall be primed in accordance with MIL-STD-7179 or MIL-PRF-85582, Type I, Class
C1 or C2 epoxy primer and allowed to completely cure prior to installing the fastener. These
fasteners shall be installed with corrosion preventive compound. Maintenance instructions shall
require periodic reapplication of this material in-service.
4.6.13.1 Fasteners in titanium. Titanium, Monel, and stainless steel fasteners installed in
titanium structures may be installed dry, unless sealing is required for liquid tightness or
pressurization. Titanium fasteners in contact aluminum shall be wet installed.
4.6.13.2 Fasteners in graphite composites. Fastener materials for use in carbon fiber
reinforced composite structures shall be titanium, A286, or Inconel 718. Cadmium plated
fasteners and aluminum fasteners shall not be used.
4.6.13.3 Monel and stainless steel fasteners. Monel fasteners or stainless steel fasteners shall
be coated with cadmium or aluminum when used in contact with aluminum components.
4.6.13.4 Interference fit fasteners. Cadmium plated interference fit fasteners shall not be
used in contact with titanium. Fastener holes for interference fit fasteners shall be primed with
MIL-PRF-23377, Type I, Class 1 or 2 or MIL-PRF-85582, Type I, Class 2 and shall be
completely dry prior to assembly. Wet installation may be waived when using pre-coated
fasteners if approved by the CEA.
4.6.14 Special considerations.

4.6.14.1 Signature control. Materials, processes, primary and secondary structures used to
achieve signature control shall be evaluated in accordance with SAE ARP4118 and MIL-STD-
889 for corrosion resistance in full stack-up representative assemblies.
4.6.14.2 Fluids, lubricants and their containment. Only qualified military specification
materials shall be used for hydraulic fluids, coolants, greases, gas turbine oils, and other
functional fluids. Phosphate ester based hydraulic fluids (such as Skydrol®) are not active for
new design.
4.6.14.3 Greases. MIL-PRF-32014, a corrosion-resistant lithium soap grease, shall be used in

lieu of MIL-PRF-81322 and other clay thickened or non-corrosion inhibited greases in
applications where the operating temperature is less than 350 °F (176 °C). For gaseous oxygen
compatibility requirements or high temperature applications, perfluorinated greases in
22
MIL-STD-1568D
accordance with MIL-PRF-27617 shall be used. Greases in accordance with MIL-PRF-32014

can be used above 350 °F (176 °C) if the performance is evaluated with component level testing.
4.6.14.4 Coolant. For radar cooling systems, polyalphaolephin (PAO) based coolant in
accordance with MIL-PRF-87252 shall be used.
4.6.14.5 Fluorocarbon seals. Fluorocarbon seals in accordance with SAE AMS7276, SAE
AMS7259, SAE AMS7287, or SAE AMS7379 shall be used.
4.6.15 Electronic or avionics systems. All electronic assemblies and avionics shall be in
accordance with J-STD-001, MIL-M-38510, and MIL-HDBK-1250. Electrical wiring
interconnect systems (EWIS) shall be in accordance with SAE AS50881 and MIL-HDBK-1250.
4.6.16 Firefighting agents. Fire extinguishing agents such as Fire Fighting Foam (FFF),
bromochloromethane dibromochloromethane or dry powder agents such as potassium
bicarbonate or sodium bicarbonate after exposure to heat are corrosive. Decontamination
procedures require flushing with generous quantities of water in conjunction with
washing/rinsing of all surfaces and components exposed to fire suppressant materials. To the
extent possible, designs shall minimize areas of potential exposure to these materials and
facilitate the flushing and cleaning of those areas exposed.
4.6.17 Wear and erosion. The design and manufacture of aircraft shall include practices to
minimize damage by wear and erosion. Coatings for the prevention of wear and erosion shall be
in accordance with MIL-STD-7179.
4.6.18 Lubrication. Provisions shall be made for lubrication of all parts subject to wear
using lubricants from MIL-HDBK-275 as specified in MIL-HDBK-838. The fire resistant
synthetic hydrocarbon hydraulic fluid in accordance with MIL-PRF-83282 shall be used as the
aircraft hydraulic fluid in operating temperatures down to -40 °F (-40 °C). For operating
temperatures down to -65 °F (-54 °C), MIL-PRF-87257 shall be used. Multipurpose lubricants
such as the wide temperature general purpose grease described in 4.6.14.3 shall be used
whenever possible, without compromising performance and reliability. Components that are
highly loaded/dynamic and in potentially corrosive environments (e.g., landing gear, arresting
gear) shall make maximum use of lubrication fittings, versus other forms of lubricants.
4.6.19 Support equipment. All unique support equipment procured as a part of the
aerospace weapons system acquisition shall be designed using the guidance provided in
MIL-HDBK-808.
4.6.20 Welded components. Welding of aerospace components shall be performed in

accordance with AWS D17.1/D17.1M or an equivalent specification approved by the CEA.
4.7 Verification of corrosion design. Aerospace weapon systems are usually designed for
specified lifetimes with maintenance according to defined maintenance concepts and plans.
Where possible, include formal specific corrosion criteria in the environmental test plans to
include evaluation for moisture collection, sealing, etc. Specific corrosion testing shall be
conducted on components and subsystems in accordance with ASTM B117 (and ASTM G85.A4
23
MIL-STD-1568D
for Naval systems only). The systems shall have negligible corrosion, as determined by the CEA,
while maintaining functionality after 500 hours of ASTM B117 testing of the assembled
production configuration. Additionally for naval systems, these assemblies shall be tested to 500
hours of ASTM G85.A4. Finish and corrosion protection verification shall be in accordance with
Table III.
TABLE III. Corrosion protective coatings verification.
Test Criteria
ASTM D2247 30 day humidity test No blistering, softening, loss of adhesion or

other film defect
ASTM B117 2000 hours salt spray test with No blistering, lifting of coating nor substrate
scribed panels corrosion.
ASTM G85.A4 500 hours SO2 salt spray test No pitting greater than 1 millimeter in depth.
with scribed panels (Navy Only)
ASTM D2803 1000 hours filiform No filiform corrosion extending
corrosion test with scribed panels. beyond ¼ inch from the scribe.
4.7.1 Engine corrosion testing. Engine materials and coatings shall be corrosion tested under
simulated engine environmental conditions commensurate to their final usage during operation,
handling, and storage of the engine. For this testing, a new or newly overhauled engine shall be
used. Prior to starting the test, the engine shall be disassembled and an inspection shall be
conducted to determine the condition of all parts exposed to atmospheric conditions. Detailed
photographic coverage of these parts shall be used for comparison with post-test conditions. The
engine shall then be reassembled, pretest performance shall be calibrated, and subject to 25
accelerated mission test (AMT) cycles while being injected with a two percent of airflow weight
spray solution, consisting of the following materials dissolved with distilled water to make one
liter of salt spray solution.
Chemical designation Quantity per liter of spray solution
NaC1 (c.p.) 23 grams
Na2SO4.10H2O 8 grams
Stock solution (See recipe below) 20 milliliters
The stock solution shall be composed of the following materials dissolved with distilled
water to make one liter of stock solution:
Chemical designation Quantity per liter of stock solution
KC1 (c.p.) 10 grams
KBr 45 grams
24
MIL-STD-1568D
MgC12.6H2O (c.p.) 550 grams
CaCl2.6H2O (c.p.) 110 grams
At specified intervals during the test, the engine shall be subjected to internal inspections to
detect any evidence of corrosion or progression of corrosion on internal parts. Upon completion
of the test, a performance check shall be conducted and the engine disassembled and inspected
for evidence of corrosion. Detailed photographs shall be taken of all parts that show evidence of
corrosion. The test results shall be considered satisfactory when the extent of corrosion is not
such a magnitude as to impair structural integrity or component operation, or be a cause of
significantly reducing performance, engine durability, or parts.
5. DETAIL REQUIREMENTS (Not applicable.)
6. NOTES
(This section contains information of a general or explanatory nature that may be helpful, but
is not mandatory.)
6.1 Intended use. This standard is intended to provide Department of Defense Program
Offices with a document that provides timely and comprehensive consideration during systems
design of corrosion prevention and control processes and of the lessons learned over the years
from operational systems worldwide. System reliability and maintainability will be significantly
improved by the use of this standard. It should be used in conjunction with MIL-HDBK-1587 in
selection of materials and processes that will meet the requirements of the systems being
designed in accordance with MIL-STD-1530.
6.2 Acquisition requirements. Acquisition documents should specify the following:
a. Title, number, and date of this standard.
b. Corrosion Prevention and Control Plan (CPCP) (see 4.1).
c. Finish specification (see 4.2).
d. If Nondestructive Inspection (NDI) is required (see 4.5.6.1).
e. Timelines and milestones for the CPCP and finish specification (see Appendix A).
f. The establishment of Corrosion Prevention Teams (CPTs) (see Appendix B).
25
MIL-STD-1568D
6.3 Associated Data Item Descriptions (DIDs). This standard has been assigned an
Acquisition Management Systems Control (AMSC) number authorizing it as the source
document for the following DIDs. When it is necessary to obtain the data, the applicable DIDs
must be listed on the Contract Data Requirements List (DD Form 1423).
DID Number DID Title
DI-MFFP-81402 Finish Specification

DI-MFFP-81403 Corrosion Prevention and Control Plan
The above DIDs were current as of the date of this standard. The ASSIST database should be
researched at http://quicksearch.dla.mil to ensure that only current and approved DIDs are cited
on the DD Form 1423.
6.4 Subject term (key word) listing.

Cadmium plated Sealants
Metal finishes Stress corrosion
Organic coatings
6.5 Alternate materials and processes. Justification data, including both laboratory and
service experience, will be required for CEA approval of any alternate materials and processes.
6.6 Document websites and historical information websites. Relevant documents and
historical information can be found by accessing the links below:
http://www.corrdefense.org
http://www.dscc.dla.mil/Programs/MilSpec/DocSearch.aspx
http://quicksearch.dla.mil
www.grantadesign.com (Cambridge Material Selector)
6.7 Changes from previous issue. Marginal notations are not used in this revision to identify
changes with respect to the previous issue due to the extent of the changes.
26
MIL-STD-1568D
APPENDIX A
CORROSION PREVENTION AND CONTROL PLAN (CPCP)

AND FINISH SPECIFICATION
A.1 SCOPE
A.1.1 Scope. This appendix details the timeline and milestones for the submission of a
corrosion prevention and control plan (CPCP) and finish specification (see 6.2e). This appendix
is not a mandatory part of the standard. The information contained herein is intended for
guidance only.
A.1.2 CPCP submission timeline. The initial draft of the corrosion prevention and control
plan must be submitted to the procuring activity as part of the proposal package 60 days prior to
the System Requirements Review (SRR), Milestone A. The submittal of the corrosion
prevention and control plan and the finish specification must occur 60 days prior to System
Design Review (SDR), Milestone B. Follow-on revision and submittal of these documents must
be accomplished 60 days prior to Preliminary Design Review (PDR), Critical Design Review
(CDR) and as required to properly record a change to materials and processes being selected for
corrosion prevention and control. Through design studies, analysis of failure reports and on-site
inspections, data must be collected and analyzed for revisions to these documents. For
sustainment initiatives, the CPCP and the finish specification must be adjusted accordingly and
submitted 45 days after the procurement vehicle is signed.
27
MIL-STD-1568D
APPENDIX B
CORROSION PREVENTION TEAMS (CPTs)

B.1 SCOPE
B.1.1 Scope. This appendix details the procedure for establishing a corrosion prevention
team (CPT) (see 6.2f). This appendix is not a mandatory part of the standard. The information
contained herein is intended for guidance only.
.
B.2 PROCEDURE
B.2.1 Corrosion Prevention Team (CPT). A Government-only CPT must be established

during the conceptual design phase of the program prior to Milestone A outlined in Appendix A.
This government-only team, designated by the program manager, provides technical support
during proposal evaluation. After contract, a contractor-only CPT (also referred to as the
Contractor Corrosion Team [CCT]) must be established to ensure that adequate CPC
requirements are being implemented during all phases of the aerospace weapons
systems/equipment lifecycle.
B.2.2 Government/contractor membership. Each team must consist of, as a minimum, a

Team Lead, and members from Program/Project Management, Systems Engineering, Life Cycle
Logistics, Test and Evaluation, Facilities, Materials and Processes, Design, Quality Assurance,
Manufacturing, Contracts, etc. Membership suggestions are in the “Corrosion Prevention and
Control Planning Guidebook for Military Systems and Equipment.” Each CPT is unique and is
tailored several times during the life cycle of the system to satisfy the changing requirements of
the program.
B.3 DUTIES
B.3.1 Duties of the Corrosion Prevention Team (CPT). The team must:
- Define operating procedures, and prescribe appropriate specifications and standards to be
used in the system/equipment
- Outline or document the RFP and contract requirements necessary to execute the CPCP
- Address system/equipment definition, design, engineering development, production, and
sustainment phases, ensuring they are consistent with the design life and affordability of the
system/equipment
- Develop options for finish and coating systems to be used on the procured
system/equipment
- Review all design considerations, material selections, costs, and documentation, including
Statements of Work (SOWs) that may affect CPC throughout the life of the
system/equipment.
28
MIL-STD-1568D
APPENDIX B
- Advise the PM on corrosion-related issues, confirm the adequacy of the corrosion

maintenance documentation and guidance as they are developed, and elevate unresolved
issues.
B.3.2 Duties of the Contractor Corrosion Team (CCT). The CCT must:
- Ensure that adequate CPC requirements are being implemented during all phases of the
aerospace weapons system being procured.
- Ensure appropriate documents outlined under the CPCP are prepared and submitted in
accordance with the required schedule
- Obtain the necessary design reviews, clarification, resolution of any differences in
technical position and final approval of the documentation on a timely basis.
The chairperson’s duties include:
a. Serving on the Corrosion Prevention Team (CPT) (for Air Force, this is also
referred to as the Corrosion Prevention Advisory Board [CPAB]) as required.
b. Establishing periodic meetings as required to resolve problems as they occur.
Other meetings should be convened, as required, or when a critical or major
problem arises that requires action by the team.
c. Signing off (or designee) on all production drawings after review of materials
selection, treatments and finishes.
d. Maintaining a continuing record of all action items and their resolutions.
e. Establishing the principal tasks to be accomplished to implement CPC
procedures in the contractor and subcontractor manufacturing facilities.
B.4 Implementation of a Corrosion Prevention Advisory Board (CPAB). When required by

the service program, the Government program manager must establish a CPAB at the start of the
Engineering Manufacturing Development Stage (Milestone B as specified in Appendix A). This
joint Government and contractor board, co-chaired by both a Government and prime contractor
representative, must be established to advise the program manager on corrosion related issues,
such as, design considerations, selection of materials and processes, program management,
documentation, supportability, reliability, maintainability, sustainability and structural integrity.
The CPAB should meet on a regular basis in accordance with the established board charter
throughout the life of the aerospace weapons system to ensure program continuity and should
also be utilized during sustainment initiatives.
B.4.1 CPAB membership. CPAB membership must include authoritative representatives

from appropriate Government and contractor organizations necessary to ensure that proper
materials, processes, and treatments are selected and subsequently properly applied, and
maintained from the initial phase through the life cycle of the system. Suggestions on
membership are in the “Corrosion Prevention and Control Planning Guidebook for Military
Systems and Equipment.”
29
MIL-STD-1568D
APPENDIX B
B.4.2 CPAB charter. A charter must be established at the start of Milestone B after the
CPAB is organized. A charter consists of an introduction, purpose, membership (Government
and contractor), responsibilities (Government and contractor), procedures and an appendix
addressing the membership and contact information.
30
MIL-STD-1568D
APPENDIX C
MISCELLANEOUS FACTORS AFFECTING CORROSION
C.1 SCOPE
C.1.1 Scope. This appendix details miscellaneous factors that affect corrosion. This
appendix is not a mandatory part of the standard. The information contained herein is intended
for guidance only.
C.2 APPLICABLE DOCUMENTS
Engineering Circular EC-434-000-003 Material Selection Restrictions List for

Navy and Marine Corps Aviation Weapons
Systems
Engineering Circular EC-434-000-004 Risk Mitigation for Non-chromate Coating
Systems
Engineering Circular EC-434-000-005 Corrosion Prevention and Control for Navy
and Marine Corps Aviation Systems
(Copies of these documents are available from the following address: Commander,
NAVAIRSYSCOMHQ, Head, Materials Engineering Division, Code 4.3.4, Building 2188,
47123 Buse Rd., Unit IPT, Patuxent River, MD 20670.)
DEFENSE FEDERAL ACQUISITION REGULATION SUPPLEMENT (DFARS)
Subpart 223 Environment, Energy And Water Efficiency, Renewable
Energy Technologies, Occupational Safety, And Drug-Free
Workplace
Subpart 252 Solicitation Provisions and Contract Clauses
(Copies of these documents are available at http://www.dcaa.mil/dfars.html.)
C.3 MISCELLANEOUS INFORMATION
C.3.1 Microbially Influenced Corrosion (MIC). MIC can occur in a variety of locations
such as fuel systems (i.e., tanks, pipelines) or areas that experience high humidity, standing
water, entrainment of water, or pooled or leaked operational fluids. MIC may be indicated by the
presence of “slime,” sludge or fungus. Water or fuel that has a foul or acidic (e.g., vinegar) odor
or a cloudy, flocculent appearance can also indicate the presence of microbes. MIC should be
investigated in corrosion associated with water or fuel with these characteristics. If MIC is
suspected, it should be reported to the fuel quality control agency for each branch of service
(e.g., Air Force Petroleum Agency). Microbiologists should be consulted to help identify if MIC
is present and what options can be used to mitigate the MIC.
31
MIL-STD-1568D
APPENDIX C
C.3.2 Material restrictions for Navy and Marine Corps Aircraft. Engineering circular
EC-434-000-003 provides information on the hazards or restrictions for the use of materials and
processes, not only for environmental, safety, and health concerns, but also for minimizing
adverse effects on systems due to poor design.
C.3.3 Hexavalent chromium regulations. Hexavalent chromium (Cr6+) is a chemical that

has been used for decades in numerous DoD weapons systems and platforms due to its corrosion
protection properties. However, Cr6+ is a known carcinogen. Defense Federal Acquisition
Regulation Supplement (DFARS) Subparts 223 and 252 mandate programs to minimize the use
of materials containing Cr6+ in items acquired by DoD. It codifies a DoD policy for addressing
the serious human health and environmental risks related to the use of Cr6+. The rule prohibits the
delivery of items containing more than 0.1 percent by weight Cr6+ in any homogeneous material
under DoD contracts unless there is no acceptable alternative to the use of Cr6+. The mandatory
prohibition does not apply to legacy weapons systems (developed before 2012), unless they are
undergoing a major modification. Even for new and modified systems, it is not intended to
preclude the use of Cr6+ for critical defense applications for which there are no alternatives that
can meet performance requirements. If the program manager determines that Cr6+ is necessary
for the weapons system until viable alternatives are proven, the program may seek an
Authorization Request for the contract. The authorization request is developed by the program’s
Environment, Safety and Occupational Health (ESOH) Coordinator and the Corrosion Subject
Matter Expert (SME). The authorization must be approved by the Senior Approving Official in
conjunction with the Military Department’s Corrosion Control and Prevention Executive. Further
guidance for Naval Programs is available in Appendix 1 of Engineering Circular EC-434-000-
005 and Engineering Circular EC-434-000-004.
32
MIL-STD-1568D
CONCLUDING MATERIAL
Custodians: Preparing activity:

Army - MI Navy - AS
Navy - AS (Project MFFP-2015-003)
Air Force - 20
Review activities:
Army - AV
Navy - CH, EC, MC, OS, SA, SH, YD
Air Force - 11
NOTE: The activities listed above were interested in this document as of the date of this
document. Since organizations and responsibilities can change, you should verify the currency
of the information above using the ASSIST Online database at https://assist.dla.mil.
33

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AMSC 9572 AREA MFFP

2. Comments, suggestions, or questions on this document should be addressed to:

2. APPLICABLE DOCUMENTS .................................................................................................... 2

4. GENERAL REQUIREMENTS .................................................................................................... 9

4.4 Materials and process considerations in design .......................................................................... 10

4.6.9 Protection of parts during storage and shipment...................................................................... 19

5. DETAIL REQUIREMENTS ........................................................................................................ 25

CONCLUDING MATERIAL .......................................................................................................... 33

A. CORROSION PREVENTION AND CONTROL PLAN (CPCP) AND FINISH

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards,

TT-C-490 - Chemical Conversion Coatings and Pretreatments for

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-5002 - Surface Treatments and Inorganic Coatings for Metal

MIL-PRF-83282 - Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon Base,

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-186 - Protective Finishing For Army Missile Weapon Systems

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-275 - Guide for Selection of Lubricants, Fluids, and Compounds

(Copies of these documents are available online at https://assist.dla.mil.)

DoDD 5000.01 - The Defense Acquisition System

(Copies of this document are available online at http://www.dtic.mil.)

(Copies of this document are available online at

DEFENSE FEDERAL ACQUISITION REGULATION SUPPLEMENT (DFARS)

Subpart 207.105 - Acquisition Planning: Contents of Written Acquisition Plans

(Copies of these documents are available at http://www.dcaa.mil/dfars.html.)

ASTM A380/A380M - Standard Practice for Cleaning, Descaling, and Passivation of

ASTM D2247 - Standard Practice for Testing Water Resistance of Coatings

(Copies of these documents are available online at http://www.astm.org.)

IPC Association Connecting Electronics Industries

J-STD-001 - Requirements For Soldered Electrical And Electronic

(Copies of this document are available online at http://www.ipc.org.)

SAE AMS-QQ-N-290 - Nickel Plating (Electrodeposited)

SAE AMS3278 - Sealing and Coating Compound: Polyurethane (PUR) Fuel

(Copies of these documents are available online at http://www.sae.org.)

AMERICAN WELDING SOCIETY (AWS)

AWS D17.1/D17.1M - Fusion Welding for Aerospace Applications

(Copies of this document are available online at http://aws.org.)

a. prevent the start of corrosion

3.15 Microbially Influenced Corrosion (MIC). Corrosion that is caused or promoted by

3.16 Nondestructive Inspection (NDI). The inspection of a structure or component in any

structure or composition, or it may characterize physical, electrical, or thermal properties without

a. System design, engineering and manufacturing requirements, operations, logistics, and

including low observable materials.

4.3 Sustainment. Since corrosion prevention, control, and mitigation contribute

4.4 Materials and process considerations in design.

4.4.3 Alternate manufacturing processes. Components produced using alternate

4.5 General design requirements for corrosion prevention.

4.5.4 Galvanically dissimilar materials. Use of dissimilar metals in contact, as specified in

4.5.5 Insulation/acoustic blankets. When required, insulation/acoustic blankets shall be

4.6 Metallic materials.

d. Steels shall be selected to have ductile-brittle fracture transition temperatures as

f. Critical parts shall be designed and processed so as to result in no decarburization in

i. Aeromet 100 shall be procured in accordance with SAE AMS6532.