Why New Planes Fly Naked: The Unseen World of Aircraft Primer
The Royal Air Force's second E-7 Wedgetail recently flew out of Birmingham in its unfinished state, sporting an unlovely metallic green primer. This is a common sight in aircraft manufacturing, as few people get to see planes during this stage before they are painted and completed.
The green primer is not just for show; it serves a purpose. The zinc chromate primer used to protect the aluminum alloy from corrosion is yellow on its own but turns green when lampblack is added, improving UV resistance. This coating is essential in preventing moisture, oils, and oxidation from attacking the bare metal.
Airbus A380s take around 950 gallons of paint, adding roughly 2,425 pounds to their weight. Boeing 777s carry around 555 pounds once dry, with over half a ton while still wet. This extra weight flies on every sector for the life of the aircraft, which is why airlines spend real engineering effort to shave off a few kilograms from their coatings.
EasyJet has been working with Mankiewicz Aviation Coatings to develop a new lightweight paint that will save 27 kilograms per aircraft. By 2030, they expect this reformulated livery to cut fuel burn by 1,296 tonnes a year, equivalent to around 4,095 tonnes of carbon dioxide.