PROCESS AND MATERIAL SPECIFICATION

01-02-71

Coating Removal by Means of a Laser Technique for Preparation of

Electrical Bonding Connections

The content of this document is the property of Airbus. It is supplied in confidence and commercial security on its contents must be
maintained. It must not be used for any purpose other than that for which it is supplied, nor may information contained in it be
disclosed to unauthorized persons. It must not be reproduced in whole or in part without permission in writing from the owners of the
copyright.
© AIRBUS 2020. All rights reserved.

AIPI05-03-006 PMS Ref: 01-02-71

Issue: A1 Rev: FEB 01/21
 AIRBUS
PROCESS AND MATERIAL SPECIFICATION
AIPI05-03-006
Issue A1
Page 1 of 16

AIPI
Airbus Process Instruction

Coating removal by means of a laser technique for preparation of

electrical bonding connections

Published and distributed by:

AIRBUS Operations S.A.S.
MANUFACTURING-ENGINEERING DIRECTORATE
31707 BLAGNAC Cedex
FRANCE

© Copyright AIRBUS Operations S.A.S. 2019. All rights reserved

Ref. No. AIPI05-03-006

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CONTENTS

1 GENERAL ......................................................................................................................3
1.1 Purpose ..................................................................................................................3
1.2 Scope and limitations ..............................................................................................3
1.2.1 Scope..................................................................................................................3
1.2.2 Limitations ...........................................................................................................3
1.2.3 Information on drawings ......................................................................................3
1.3 Normative references ..............................................................................................3
1.4 Definition .................................................................................................................4
1.5 Specificities .............................................................................................................4
2 MEANS TO BE EMPLOYED AND SHOPFLOOR/FACILITIES CONDITIONS ................5
2.1 Products and materials ...........................................................................................5
2.1.1 Parts/materials exposed to the process...............................................................5
2.1.2 Non-conductive layer ..........................................................................................5
2.1.3 Auxiliary materials and consumables ..................................................................5
2.2 Tools, machines and equipment .............................................................................5
2.3 Shopfloor/facilities conditions ..................................................................................6
3 PROCESS ......................................................................................................................7
3.1 Preparation of the work ...........................................................................................8
3.1.1 Part preparation ..................................................................................................8
3.1.2 Part positioning ...................................................................................................8
3.1.3 Selection of the appropriate pre-adjusted JOB file...............................................8
3.2 Operations description ............................................................................................8
3.2.1 Laser treatment ...................................................................................................8
3.3 Completion..............................................................................................................8
3.3.1 Cleaning ..............................................................................................................8
3.3.2 Inspection ...........................................................................................................8
3.3.3 Rework ................................................................................................................8
3.3.4 Conditions of storage and transportation .............................................................8
3.4 Key Process Parameter ..........................................................................................9
3.5 Implementation .......................................................................................................9
4 PROCESS QUALITY ASSURANCE AND FOLLOW-UP...............................................10
4.1 Serial production inspections ................................................................................10
4.1.1 Process control .................................................................................................10
4.1.2 Visual inspections .............................................................................................10
4.1.3 Electrical resistance measurements ..................................................................11
4.1.4 Microscopic inspections ....................................................................................11
4.2 Quality control and monitoring...............................................................................11
4.3 FOD Foreign Object Damage................................................................................11
5 ENVIRONMENT, HEALTH AND SAFETY ....................................................................11
6 APPENDICES ..............................................................................................................11
6.1 List of figures ........................................................................................................11
6.2 List of tables..........................................................................................................11
6.3 Technical specification of laser devices & parameters of operations .....................12
6.3.1 Laser device 1...................................................................................................12
6.3.2 Laser device 2...................................................................................................13
GLOSSARY .........................................................................................................................15
RECORD OF REVISIONS ...................................................................................................16

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1 GENERAL
1.1 PURPOSE
This AIPI details the manufacturing process required to comply with the associated
AIPS05-03-006. It defines the method and tools for “Coating removal by means of a
laser-technique for preparation of electrical bonding connections”.

1.2 SCOPE AND LIMITATIONS

1.2.1 SCOPE
The process described in this document applies to remove non-conductive surface protections
(i.e. topcoat finish, paint primer, anodizing layer) on aluminum alloy surfaces to produce an
electrical conductive (metallic bright) surface.
This process serves as alternative to the use of masking/adhesive tape before coating and
the use of a rotating brush to remove the non-conductive surface protection for rework if
paint undercut appears.

1.2.2 LIMITATIONS
This process does not apply:
- For paint stripping if applied for other purposes than for electrical bonding
connections.
- For non-flat surfaces (unless demonstrated that the insulation layer is removed
completely and the induced laser energy-density per time is negligible for the base
material properties.)
- For parts subjected to fatigue loads (unless it is considered from design authority).
Exception: if laser operation is conducted around fastener hole.

1.2.3 INFORMATION ON DRAWINGS

The area where the surface protection has to be removed for electrical bonding purposes is

indicated in the drawing/definition dossier by the symbol . It shall be ensured that only the
surface protection designated for electrical bonding is removed.

1.3 NORMATIVE REFERENCES

Only references cited in the document are listed hereafter. The latest issue of the publication
referenced shall be used:
ISO11553 Safety of machinery – Laser processing machines
EN12254 Screens for laser working places – Safety requirements and testing
EN60825-1 Safety of laser products – Part 1: Equipment classification and
requirements
EN60825-4 Safety of laser products – Part 4: Laser guards
ABS1659 ESN Raceway
AIPI03-03-001 Rework of scratches in aluminium and aluminium alloys on external
surfaces
AIPI09-01-002 Cleaning with liquid non aqueous agents
AIPS05-03-006 Coating removal by means of a laser technique for preparation of
Electrical Bonding Connections
AIPI07-01-006 Electrical Bonding

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1.4 DEFINITION
Shop floor condition:
Closed and secured area in factory where laser operation is performed.
Electrical Bonding:
Electrical bonding refers to the establishment of a current path between electrically
conductive parts in order to assure electrical continuity.
Non-conductive surface protection:
A non-conductive surface protection is a coating that limit the transfer of electricity to
the metal substrate with the coating applied.
Working distance:
The working distance is the distance from the head of the laser to the surface of the
part to be treated.
Focal length:
The focal length is the distance from the converging lens to the surface of the part to
be treated.
JOB file:
The “JOB file” is a computer control file containing all the parameters related to a
dedicated laser treatment operation.
Footprint/laser spot:
The footprint, or laser spot, is the size of the area on a surface illuminated by the laser.
Laser beam deflection parameters:
It contains all parameters directly manipulated by/in the laser head (over the laser
output coupler/output beam/mirror/lens etc.).

1.5 SPECIFICITIES
Before any serial operation, the set of parameters necessary to meet AIPS05-03-006
requirements for the combination of:
- Laser device and corresponding Key Process Parameter,
- Dimensions of the electrical bonding connection,
shall be determined in shop trials, stored in a “JOB file (laser control file)” and recorded in this
AIPI.

The AIPI shall contain all process relevant parameters:

1. Laser device and corresponding Key Process Parameter,
2. Non-conductive layer (nature and thickness of the coating system), non-conductive
layer specifications,
3. Base-material, material specifications,
4. Dimensions of the electrical bonding contact surface to be prepared.

Each “JOB file” contains fixed laser parameters valid for a combination of laser device
(KPP)/non-conductive layer/base material/dimensions, which shall not be modified.
If a parameter needs to be modified, a new “JOB file” shall be created, qualified and recorded
into this AIPI. All changes of parameters shall be recorded and shall be qualified in accordance
with AIPS05-03-006.

The AIPI shall be validated before any serial operation.

It shall be demonstrated by an industrial assessment that the process qualification
requirements of AIPS05-03-006 are fulfilled. Results and release of base materials and
respective protective treatments shall be recorded.

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2 MEANS TO BE EMPLOYED AND SHOPFLOOR/FACILITIES

CONDITIONS
2.1 PRODUCTS AND MATERIALS
2.1.1 PARTS/MATERIALS EXPOSED TO THE PROCESS
Only parts made from base-materials/alloys for which it has been demonstrated successfully
by qualification that the used laser device/”JOB file” does not cause detrimental effects shall
be applied.
Parts/Materials subjected to the process shall comply with the requirements of the definition
dossier, and the material specification.
The materials/alloys shall be recorded in this AIPI.

2.1.2 NON-CONDUCTIVE LAYER

Only non-conductive layers for which it has been demonstrated successfully by qualification
that the used laser device/”JOB file” combination is capable to remove satisfactorily shall be
exposed to this process.
Non-conductive layers subjected to the process shall comply with the requirements of the
definition dossier, the material specification and process specification for the application of the
non-conductive layer.
The non-conductive layer shall be recorded in this AIPI.

2.1.3 AUXILIARY MATERIALS AND CONSUMABLES

- Personal protective equipment: goggles, gloves.
- Cleaning agents: cleaning agents shall conform to AIPI09-01-002.

2.2 TOOLS, MACHINES AND EQUIPMENT

Only laser devices declared in §6.3 shall be used.
The laser device used shall comply with the Laser Specification in §6.3.
The procedure for using the laser device and its maintenance shall be described in this AIPI.

The laser device is composed of:

- Gantry/table for positioning and fixation of the part(s),
- Computer (control for laser parameters),
- Laser Control Software (versions incl. machine software versions, user interface,
programmable logic controls and other controls which could influence the laser process),
- Laser objective/head,
- Laser cell/unit,
- Cooling system,
- Control tool for adjustment of focal/working distance (e.g. sensor for automatic
adjustment of the focal length coupled to a laser mask geometry),
- Control for correct positioning of the part under the laser.
An extraction removal vacuum system of particles located near the laser head shall be used
to withdraw particles from the sublimation surface treatment

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2.3 SHOPFLOOR/FACILITIES CONDITIONS

The shopfloor is defined by a special area in the factory: closed and secured (shielding) for
laser safety specifications.
Only the personnel required for performing laser operation process shall stay in the working
area.

Operator training:
All work related to this process shall only be carried out by trained operators familiar with:
- This AIPI,
- The corresponding AIPS,
- The use and adjustment of the laser system,
- The environment,
- The health, and safety regulations.
The mandatory regulations for working with lasers of the respective country shall be considered
(see EN60825-1, EN60825-4, EN12254, and ISO11553).

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3 PROCESS

Part preparation

Part positioning

Selection of the
appropriate pre-adjusted
“JOB file”

Laser treatment

Cleaning
Rework

Non acceptable
Inspection

Acceptable

Subsequent treatment

Figure 1 – Process flowchart

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3.1 PREPARATION OF THE WORK

3.1.1 PART PREPARATION
Before processing, parts shall be cleaned in accordance to AIPI09-01-002.

3.1.2 PART POSITIONING

The parts shall be handled carefully with cotton gloves to avoid recontamination and damages.
The part shall be fixed at the positioning table in a way to avoid any unintended part movement
during the laser operation process.

It is required that the part is in the correct location and perpendicular to the laser beam (on the
horizontal and vertical axes).

3.1.3 SELECTION OF THE APPROPRIATE PRE-ADJUSTED JOB FILE

From the laser computer, select the appropriate “JOB file” according qualified parameters of
this AIPI and in accordance with the definition dossier/work order, as described in §6.3.

3.2 OPERATIONS DESCRIPTION

3.2.1 LASER TREATMENT
From the laser computer, run the “JOB file” in order to start the laser operations.

3.3 COMPLETION
3.3.1 CLEANING
All traces of dust or particles resulting from the laser operations shall be removed according to
AIPI09-01-002.

3.3.2 INSPECTION
For serial production inspection and quality control and monitoring, see §4.

3.3.3 REWORK
Two possibilities of rework process are possible:
- Case 1 - Incomplete removal of non-conductive layer:
Use the stripping method according to AIPI07-01-006 or repeat laser treatment up the
maximum qualified number of crossing, as described in §6.3.
- Case 2 - Incorrect positioning:
Rework of surface treatment according to AIPI03-03-001.

Alert the quality department for further decision in case of result not covered
by this chapter.

3.3.4 CONDITIONS OF STORAGE AND TRANSPORTATION

The storage and transportation conditions shall respect the requirements according to
AIPI07-01-006.
Maximum allowed time between laser treatment and electrical bonding process shall be in
accordance with AIPI07-01-006.

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3.4 KEY PROCESS PARAMETER

The KPP table is defined following A1356.
AIPI No Reference: AIPI 05-03-006 Issue A1
Acceptance criteria
KPP Numbering Process
Continuous Variable
KPP Designation Recommended Control Action Discrete Capability
Lower Nominal Upper
Related Numbering Type Unit Status Impact
limit value limit
The removal of the non-conductive surface protection
Removal of non-conductive shall be demonstrated by the Ohmic Resistance Test.
AIPI 05-03-006.0001 KC <5 mOhm N
surface protection Test specimen, test method and requirements for the
Ohmic Resistance Test are defined in AIPS07-01-006.
AIPI 05-03-006.0003 CTI Positioning of the part The part is positioned in correct location, as per §3.1.2. YES/NO N

AIPI 05.03.006.0004 Temporary protections Presence of temporary protections.

R-0001 Surface aspect Without default and corrosion. YES/NO N

±5% of the
Weekly checking according to technical specification for
R-0002 Laser power optimal N
metallic parts.
power
R-0003 Cleanliness of the optical lens Daily Check before start production. YES/NO N

Laser device set with parameters (JOB file) related to the

AIPI 05.03.006.0005 CTI Laser parameters YES/NO N
operation and material, as per §6.3.

The working distance shall be controlled within the

AIPI 05.03.006.0006 CTI Working distance YES/NO N
qualified tolerances, as per §6.3.

The area to be treated is aligned with the laser beam, as

AIPI 05.03.006.0007 CTI Position of the area to treat YES/NO N
per §3.1.2.

Parts are free from contaminations such as grease or any

AIPI 05.03.006.0008 CTI Cleanliness of the part YES/NO N
flammable residua at the surface, as per §3.1.1.

AIPI 05.03.006.0009 CTI Cleanliness of the optical lens Daily check before start production. YES/NO N

3.5 IMPLEMENTATION
N/A

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4 PROCESS QUALITY ASSURANCE AND FOLLOW-UP

4.1 SERIAL PRODUCTION INSPECTIONS
4.1.1 PROCESS CONTROL
The parameters related to the operation of the device shall be continuously monitored, and
documented by the system.
The operator shall perform the series production inspections under serial conditions (including
checks after each process step, and final visual inspection).

4.1.2 VISUAL INSPECTIONS

After the laser operations, the operator has to carry out a visual inspection of the process.
In case of non-conformity, always refer to the Quality Department.

Process acceptance criteria for metallic parts:

Acceptable

Non-conductive layer completely removed.

Incomplete removal of non-conductive layer.

Not acceptable

Incorrect positioning of the part on the gantry.

or
Incorrect positioning of the laser head on the part.

Incorrect diameter of the removed non-conductive layer.

All parts with a non-conformity not listed above shall be assessed by the
Quality Department.

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4.1.3 ELECTRICAL RESISTANCE MEASUREMENTS

Electrical resistance measurements shall be done in accordance to AIPI07-01-006.

4.1.4 MICROSCOPIC INSPECTIONS

In case of irregularities on the surface detected during visual inspection, a microscopic
inspection shall be performed in order to check remaining contamination, remaining protective
layer, or surface damages etc.

4.2 QUALITY CONTROL AND MONITORING

Check part by visual inspection as per §4.1 and assess if a rework is possible according to
§3.3.3.
Control the laser device regularly for proper operation.
The reports demonstrating the “JOB files” non-conductive layer/base material combinations
shall be provided on the demand of the owner of this process instruction.

Table 1: Main parameters to be monitored

Parameters to be monitored Requirements
Laser source power measurement frequency 1 week

4.3 FOD FOREIGN OBJECT DAMAGE

N/A.

5 ENVIRONMENT, HEALTH AND SAFETY

The manufacturing process shall be in line with Airbus EHS policy. Be compliant with the
A1027.1.
This Process Instruction does not include the necessary measures to be adopted from the
Health and Safety country’s point of view. This is part of the MNI.
It is the responsibility of the user of this process instruction to consult and establish appropriate
Health and Safety precautions and the method should be operated only by trained personnel.

DANGER – RISK OF INJURY TO THE EYES – EYE PROTECTION IS

NECESSARY BEYOND THIS POINT.

This symbol indicates that tests are ongoing and require the use specific of protective eyewear.
Wearing glasses adapted to the wavelength required. These glasses are issued by the
manufacturer of the device and are adapted to the type of equipment provides. Never use any
other eye protection that is not provided by the manufacturer of the device: the risk is to use
glasses not suitable wavelength and not be protected. The glasses should protect against
wavelength of 1064 nm.
Wearing protective gloves is required.

6 APPENDICES
6.1 LIST OF FIGURES
Figure 1 – Process flowchart ..................................................................................................7

6.2 LIST OF TABLES

Table 1: Main parameters to be monitored ...........................................................................11

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6.3 TECHNICAL SPECIFICATION OF LASER DEVICES & PARAMETERS

OF OPERATIONS
6.3.1 LASER DEVICE 1

Laser type
Equipment CL 150
Serial Number L10-1179
Year of manufacture 2010
Delivery date 28/05/2010
Laser data
Type of laser Nd:YAG
Operational mode q-switched
Wavelength (nm) 1 064
Class laser 4
Max. power of the laser source (W) 160
Specified power of the laser source (W) 150
Pulse frequency (kHz) 12 – 40 kHz
Max. Pulse energy (mJ) 14
Mini width of pulse (at 30kHz) (ns) 90
Expected life of diode module (h) > 20 000
Dimensions
Width (mm) 1 200
Depth (mm) 990
Height (mm) 1 850
Weight (kg) ~230
Power
Power supply 3 x 16 A
Voltage (V) 400
Frequency (Hz) 50/60
Mini. Temperature storage (°C) 5
Mini. Operating temperature (°C) 10
Maxi. Operating temperature (°C) 34
Protection according DIN 40 050 IP44
Maxi. Power consumption (VA) 5 000
Cooling system Water-Water (R134a)
Pressure (bars) 21
Nominal power (CL 150, CL300/CL500) (W) 6 000
Pump flow (L/h) 540
Pomp pressure (bars) 2,3
Model CRES
Volume of water (L) 25
Controller PID
Heating (LC) (W) 500
Liquid type LC Special
Particulate filter (—m) 5

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6.3.2 LASER DEVICE 2

6.3.2.1 Laser device’s fixed parameters

Laser type
Equipment CL 50 FFC
Serial Number L15-1610
Year of manufacture 01/04/2015
Delivery date 01/07/2015
Laser data
Type of laser Fiber (diode pumped solid state)
Operational mode q-switched
Wavelength (nm) 1 064 ± 4
Class laser 4
Max. power of the laser source (W) 50
Specified power of the laser source (W) 50
Pulse frequency (kHz) 50
Max. Pulse energy (mJ) 1,0
Mini width of pulse (at 50kHz) (ns) 80
Expected life of diode module (h) > 50 000
Dimensions
Width (mm) 483
Depth (mm) 469,5
Height (mm) 169
Weight (kg) ~27
Power
Power supply 1 x 16 A
Voltage (V) 100-240
Frequency (Hz) 50/60
Mini. Temperature storage (°C) 5
Mini. Operating temperature (°C) 10
Maxi. Operating temperature (°C) 36
Protection according DIN 40 050 IP 44
Maxi. Power consumption (VA) 400
Cooling system Air fan
Pressure (bars) N/A
Nominal power N/A
Pump flow (L/h) N/A
Pomp pressure (bars) N/A
Model N/A
Volume of water (L) N/A
Controller N/A
Heating (LC) (W) N/A
Liquid type LC N/A
Particulate filter (—m) N/A

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6.3.2.2 Laser device’s variable parameters

JOB file Laser / Machine Variable laser parameter Part / Substrate / Surface treatment Electrical bonding
Material dimensions
JOB profle_10mm AIPI Appendix 2 Working distance: 185,5 ±2 mm ABS1659 Sulfuric acid anodizing according 10 mm to 22 mm
JOB profle_12mm CL 50 FFC Al6063 T6 MIL-A-8625F Type II Class 1.
JOB profle_14mm Number of crossing: 5 mini to 25 maxi Thickness >20 ±5 μm
JOB profle_16mm
JOB profle_18mm
JOB profle_20mm
JOB profle_22mm

JOB PA21,7 x 20 mm AIPI Appendix 2 Working distance: 185,5 ±2 mm ABS1659 Sulfuric acid anodizing according 21,7 x 20 mm
CL 50 FFC Al6063 T6 MIL-A-8625F Type II Class 1.
Number of crossing: 5 mini to 25 maxi Thickness >20 ±5 μm

JOB PA22,2 x 20 mm AIPI Appendix 2 Working distance: 185,5 ±2 mm ABS1659 Sulfuric acid anodizing according 22,2 x 20 mm
CL 50 FFC Al6063 T6 MIL-A-8625F Type II Class 1.
Number of crossing: 5 mini to 25 maxi Thickness >20 ±5 μm

Rework AIPI Appendix 2 Working distance: 185,5 ±2 mm ABS1659 Sulfuric acid anodizing according 10 mm to 22 mm
CL 50 FFC Al6063 T6 MIL-A-8625F Type II Class 1. 21,7 x 20 mm
Number of crossing: 5 mini to 25 maxi Thickness >20 ±5 μm 22,2 x 20 mm

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GLOSSARY
The following words and their definitions apply within this document:
AIPI Airbus Process Instruction
AIPS Airbus Process Specification
CTI Critical Item
EHS Environment, Health and Safety
KC Key Characteristic
KPP Key Process Parameter
MNI Manufacturing Notice Instruction
N/A Not Applicable

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RECORD OF REVISIONS

Manufacturing
Modified Process
Issue Description of changes
pages & § impacted
Yes/No
1 (A0) All Creation
A1
All AIPI fully reworked Yes
(10/2019)

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