Corrosion is tendency deterioration reaction between

of the metal and environments in either of:

• Chemical attack
• Electrochemical attack.
The corrosion process always involves two
simultaneous changes a metal attack or oxidize
suffers (anodic change), and the corrosive agent is
reduced (cathodic change).
Deterioration of a material due to interaction with its
environment (water or water vapor containing salt
combine with oxygen).
Two general classifications of corrosion:
• Direct Chemical Attack
Resulting from exposure of a bare surface to caustic
liquid or gaseous agents
• Spilled battery acid or fumes from batteries
• Residual flux deposits inadequately cleaned,
welded, etc
• Entrapped caustic cleaning solutions
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Deterioration of a material due to interaction with its
environment (water or water vapor containing salt
combine with oxygen).
Two general classifications of corrosion:
• Electrochemical Attack
• Likened chemically to the electrolytic reaction
which takes place in electroplating, anodizing, or
in a dry- cell battery
• Requires a medium, usually water through which
electrons may flow

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Elimination of any one of these conditions will stop
corrosion.

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Chemical (Oxidation)
With introduction of oxide film (sealed lead-acid, use
nicad battery) to prevents the further corrosive.
Remove residual flux from the metal surface
immediately after the joining operation.
Particular attention using a cleaning solutions should
be directly toward their complete removal after use
on aircraft.
Electrochemical (Galvanic)
The reaction in this corrosive attack requires a
medium.
Occur not only on the surface of metal, also within
the granular structure of the metal.
When a metal comes in contact with a corrosive agent
and is also connected by a liquid or gaseous path
through which electrons may flow, corrosion begins
as the metal decays by oxidation.
Form of Corrosion
Surface Corrosion appears as a general roughening,
etching, or pitting of the surface of a metal (powdery
deposit of corrosion product) caused by Direct
Chemical or Electrochemical attack.
Corrosion will spread under the surface coating and
cannot be recognized, closer inspection will reveal the
paint or plating is lifted off the surface in small blisters
which result from the pressure of the underlying
accumulation of corrosion products.
Form of Corrosion.
Filiform Corrosion.
Occurs beneath thin, with the paint or coating of
bulging or blistering and very shallow.
As a result, this type of corrosion (on bearing
surfaces) has also been called false brinelling.
Form of Corrosion.
Galvanic (Dissimilar) Corrosion may result from
contact between dissimilar metal parts in the
presence of a conductor (electrochemical action of
two dissimilar metals in the presence of an electrolyte
and an electron conductive path)
The contamination of a metal’s surface by mechanical
means can also induce dissimilar metal corrosion.
• Dissimilar Metal Corrosion
Result from contact between dissimilar metal parts,
electrochemical attack can be very serious.

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Form of Corrosion.
Intergranular Corrosion (Inter crystalline) type of
corrosion is an attack along the grain boundaries of
an alloy results from a lack of uniformity caused by
changes that occur in the alloy during heating and
cooling.
Inspected this corrosion can be detected by
ultrasonic, eddy current or radiographic
• Intergranular Corrosion
Attack along the grain boundaries of an alloy.
The lack of uniformity is caused by changes that
occur in the alloy during heating and cooling.

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Form of Corrosion.
Exfoliation Corrosion.
Severe intergranular corrosion may sometimes cause
the surface of a metal to “exfoliate”, a lifting or
flaking of the metal at the surface due to
delamination of the grain boundaries caused by the
pressure of corrosion residual product buildup (just
below the surface).
Form of Corrosion.
Stress Corrosion.
As the result of the combined effect of sustained
tensile stresses and a corrosive environment, is found
in most metal.
Usually occurs during manufacturing process (residual
stress from).
Form of Corrosion.
Fretting Corrosion.
Is a particularly damaging form of corrosive attack
that occurs when two mating surfaces (rubbing),
normally at rest with respect to one another, are
subject to slight relative motion (occurs at the
interface between contacting, highly loaded metal
surfaces when subjected to slight vibratory motions).
As a result, this type of corrosion (on bearing
surfaces) has also been called false brinelling.
Form of Corrosion.
Pitting Corrosion.
Occurs when the protective film breaks down
localized corrosion and may also lead to intergranular
corrosion.
Local rough spots, contaminations and lack of
homogeneity possible cause of pitting appears of
white powder on the surface.
Form of Corrosion.
Microbiological Contamination.
Caused by directly or indirectly (one or more ways),
by micro-organism which able to produce corrosive,
but also acts as catalysts in corrosion reactions
(growth of micro-organisms in moisture traps).
Microbial corrosion (also called microbiologically -
influenced corrosion or MIC) is corrosion that is
caused by the presence and activities of microbes.
This corrosion can take many forms and can be
controlled by biocides
Factors Affecting Corrosion:
Many factors affect the type, cause, speed attack and
seriousness of metal corrosion
• Climate
Conditions under which an aircraft is maintained
and operated greatly affect corrosion
characteristics (marine environment).
Temperature considerations are important
because the speed of electrochemical attack is
increased in a hot, moist climate.
Factors Affecting Corrosion:
Many factors affect the type, cause, speed attack and
seriousness of metal corrosion
• Foreign Material
Factors which affect the onset and spread of
corrosive attack
• Soil and atmospheric dust.
• Oil, grease, and engine exhaust residues.
• Salt water and salt moisture condensation.
• Spilled battery acids and caustic cleaning solutions.
• Welding and brazing flux residues.
Preventive Maintenance.
It is important that aircraft be kept clean. How often
and to what extent an aircraft should be cleaned
depends on several factors, improvement the
corrosion resistance
• Improvement material
• Surface treatment
• Protective finishes
Corrosion preventive maintenance includes
• Adequate cleaning
• Thorough periodic lubrication
• Detailed inspection
• Daily draining of fuel, keep drain holes free
• Sealing aircraft against of water, proper ventilation
• Use protective cover
• Corrosion-Prone areas
Lavatories and galleys, they are not kept clean,
waste products may accumulate causes corrosive
attack.
Pay attention to bilge areas located under galleys
and lavatories and to personnel relief and waste
disposal vents or openings on the aircraft exteriors.

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Corrosion Removal
In general, any complete corrosion treatment involves
the following
• Cleaning and stripping of the corroded area,
• Removing of the corrosion products,
• Neutralizing any residual materials,
• Restoring protective surface films, and
• Applying temporary or permanent coatings or
paint finishes.
Surface Protection
Aircraft parts are almost given some of surface finish
by the manufacturer to provide corrosion resistance,
surface finishes may also be applied to increase wear
resistance or to provide a suitable base for paint.
Surface treatments usually include a cleaning
treatment to remove all of dirt, oil, grease, oxides,
and moisture (to provide an effective bond).
Surface Protection
The cleaning process may be either Mechanical (wire
brush, steel wool, emery cloth, sandblasting) or
Chemical (various chemical processes) depend on the
material being cleaned and the type of foreign matter
being removed.
Surface Protection
Treatment - the most common surface treatment of
nonclad aluminum alloy surfaces is Anodizing,
increases the thickness and density of the natural
oxide film.
When an anodized surface is cleaned including
corrosion removal, should avoid unnecessary
destruction of the oxide film.
Surface Protection
Alodizing is a simple chemical treatment for all
aluminum alloys to increase their corrosion resistance
and to improve their paint bonding qualities, consists
of precleaning with an acidic or alkaline metal cleaner
then rinsed with fresh water, after thorough rinsing
applied Alodine®.
Surface Protection
Permanent treatment:
• Electroplating
• Sprayed
• Cladding.
Corrosion Preventive maintenance:
• Adequate cleaning (remove dirt),
• Periodic lubrication.
• Treatment of corrosion of protective systems.
• Drain holes free obstruction

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Painting and Finishing
To protect the exposed surfaces from corrosion and
deterioration, easier to clean and maintain because
the exposed surfaces are more resistant to corrosion
and dirt, provide the desired appearance.
Term “paint” (includes primers, enamels, lacquers,
and the various multipart finishing formulas) has
three components:
• Resin as coating material,
• Pigment for color, and
• Solvents to reduce the mix to a workable viscosity.
Painting and Finishing
Paint scheme a color ideas and color preferences
should be silhouette drawing (easier to change a
drawing than to remask).
The primary objective of paint finish is to protect
exposed surfaces against corrosion and other forms of
deterioration.
Painting and Finishing
To protect from corrosion and deterioration, present a
pleasing appearance (decorative finishing includes
trim striping, logos and Emblems, decals,
identification numbers, and letters).
Painting and Finishing
Paint touchup may be required on repair to the
surface used to cover minor topcoat damage, such as
scratches, abrasions of the trim colors.
The paint system may consist of:
• A primer (base coat that improves adhesion and
inhibits corrosion),
• A compatible topcoat (the finish coating material
used over the primer), or
• A combination of primer and compatible topcoat
Surface Preparation
Properly surface preparation will results are a long-
lasting, corrosion-free finish.
Remove all soils, lubricants, and preservatives from
the surface (aluminium) scrubbed with Scotch-Brite®
pads using an alkaline aviation cleaner.
Kept wet and rinsed with clean water until the surface
is water break free (no beads or breaks in the water
surface).
Surface Preparation
Wash using a new sponge and covering a small area
while keeping it wet, then rinsed with clean water
without allowing the solution to dry on the surface.
Continue this process until all the aluminum surfaces
are washed and Rinsed.
When the surfaces are completely dry, apply Alodine®
or another type of an aluminum conversion coating,
keep it wet then be thoroughly rinsed with clean
water to remove all chemical salts.
Surface Preparation
When the surface is thoroughly dry, applied the
primer (compatible with the topcoat finish) as soon as
possible (recommended manufacturer).
The primer should be one that is compatible with the
topcoat finish.
Two-part epoxy primers provide:
• Excellent corrosion resistance and adhesion,
Urethane surfaces, and
• Polyurethane topcoats.
Surface Preparation
Epoxy sanding primers provide an excellent base over
composites, finish sanded with 320 grit using a dual
action orbital sander (compatible with two-part epoxy
primers and polyurethane topcoats).
Primer and Painting
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Painting and Finishing
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Painting and Finishing
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