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Leak Testing Fuel Tanks

We make Test Coupons for every single sealant application…
Ive been in military aerospace for a few decades and like you, I’ve seen my share of sealant laid down. We will only coupon test sealant that goes into an area that needs to be closed prior to cure (rare). That said, QA needs to buy the final cure (tack free, time and durometer) before the assembly can be sold, and of course, the final check is the soak test. I have also seen plenty of “goo” in my day, but it’s always been a mix or batch failure - not seen an environmental failure yet.

Disclaimer: “tank rats“ are artists with a horrible job - I don’t claim to be one. But it seems to me that if you are going to have a reaction to fuel at some point, best to know that while the tank is still on the bench. The “goo story” above is even MORE of a compelling reason to soak check the tanks in my mind.
 
.... I have seen plenty of 50 year old sealant that is in aircraft parked in the dry desrt for years and returned to service. ...

Sorry for the drift but it's a good example of how amazing the related products are. Hats off to the ChemEs that developed it. An ~ 60 year service life to date in some cases, sealing petroleum products that are often "unofficially" used as solvents themselves and B-52 wings flex A LOT. Impressive to my pea brain.
 
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