What Are Aircraft Fuel Tank Sealants?

Fuel tank sealants are an essential element of standard aircraft fuel systems, such components being responsible for maintaining the integrity of the tank, preventing leaks, and ensuring the overall safe operations of aircraft during flight. In this blog, we will provide a brief overview of fuel tank sealant products, allowing you to have a better understanding of what they are and how they work to keep aircraft fuel systems secure and safe.

In general, a fuel tank sealant should be made from polymer-based materials and is designed to be applied to the interior surface of the assembly. When installed, such sealants form a barrier between the fuel and tank itself, preventing the chance of fuel escaping while also guarding surfaces from corrosion. When applying a fuel tank sealant, it is critical that one follows the right process to ensure that everything is correctly cleaned and primed for a reliable and secure seal to be established.

The first step of this process is thoroughly cleaning the fuel tank to remove any possible dirt, debris, or old sealant that is present within the interior of the assembly. Furthermore, always be sure to use products compatible with your tank so as to not cause any damage, and one should always wear protective gear due to the flammability of fuel and other associated hazards. Once cleaning is done, the tank can have a primer applied to surfaces so that they are prepped for the sealant. The primer is essential as it promotes seal adhesion and further mitigates corrosion.

The fuel tank sealant itself should be applied in several layers so as to create a thick and durable coating. When choosing between sealant materials, one must consider the specific requirements of the fuel system, including any temperature or chemical resistances. Additionally, the chosen fuel tank sealant will also need to perform well under high temperatures, pressures, and with exposure to corrosive fuels.

One of the most common tank sealant options is polysulfide, and these sealants are known for being quite flexible and durable. These seals are commonly used in aviation applications and are applied in two to three coats to establish a thick and flexible sealing solution. Another common fuel tank sealant option is epoxy, and this material features ample strength and corrosion resistance. These sealants are typically applied in one or two coats.

With the proper addition and management of fuel tank sealants, one can both enhance the safety of their operations while lowering overall operational and maintenance costs by extending the lifespan of the tank. To uphold sealant quality, regular inspections should be carried out to ensure that there are no signs of deterioration, cracks, or issues that could lead to leaks. By identifying any issues early on, repairs or replacements can quickly be carried out before something leads to a more costly problem further down the line.

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