Aircraft Materials,

Construction and Repair

Corrosion
Corrosion

 Corrosion is a natural occurrence that attacks metal by

chemical or electrochemical action and converts it back to
a metallic compound.
 A substance that creates metal corrosion is called
corrosive agents. The appearance of corrosion varies with
various metals.
 The damage can take place internally as well as on the
surface.
CLASSIFICATIONS OF CORROSION

1. Direct Chemical Corrosion

 An attack resulting from a direct exposure of a bare surface to
caustic liquid or gaseous agents.

The most common agents causing direct chemical corrosion

include:
 1. Spilled battery acid or fumes from batteries.
 2. Residual flux deposits resulting from inadequately cleaned,
welded, brazed, or soldered joints.
 3. Entrapped caustic cleaning solutions.
CLASSIFICATIONS OF CORROSION
2. Electrochemical Corrosion
 Electrochemical reaction is any process either caused or accompanied
by the passage of an electric current and involving in most cases the
transfer of electrons between two substances, one a solid and the
other a liquid.
Four conditions must exist before electrochemical corrosion can occur:
 1. A metal subject to corrosion (anode).
 2. A dissimilar conductive material (cathode), which has fewer
tendencies to corrode.
 3. Presence of a continuous, conductive liquid path (electrolyte).
 4. Electrical contact between the anode and the cathode (usually in
the form of metal-to-metal contact such as rivets, bolts, and
corrosion).
Types of Corrosion

A. General Surface Corrosion

 Also referred to as Uniform Etch or
Uniform Attack Corrosion
 The most common form of corrosion and
results from a direct chemical attack on
a metal surface and involves only the
metal surface.
Types of Corrosion

B. Pitting Corrosion
 It is first noticeable as a white or gray
powdery deposit, similar to dust, which
blotches the surface.
 When the deposit is cleaned away, tiny
holes or pits can be seen in the surface.
 These small surface openings may
penetrate deeply into structural members
and cause damage completely out of
proportion to its surface appearance.
Cross sectional view
Types of Corrosion

C. Concentrated Cell Corrosion

 It is corrosion of metals in a metal-to-
metal joint, corrosion at the edge of a
joint even though the joined metals are
identical, or corrosion of a spot on the
metal surface covered by a foreign
material.
 Also known as crevice corrosion.
Types of Corrosion

D. Active-Passive Cells Corrosion

 Metals which depend on a
tightly adhering passive film,
usually an oxide, for corrosion
protection, are prone to rapid
corrosive attack by active-
passive cells.
 Active-passive cells are often
referred to as a type of
concentration cell corrosion.
 Types of Corrosion

E. Filiform Corrosion
 It is recognized by its characteristic worm-like trace of corrosion products beneath the paint film.
 This corrosion usually attacks steel and aluminum surfaces.
 The traces never cross on steel, but they will cross under one another on aluminum which makes
damage deeper and more severe for aluminum.
 Types of Corrosion

E. Filiform Corrosion
 If the corrosion is not removed,
the area treated, and a
protective finish applied, the
corrosion can lead to inter-
granular corrosion, especially
around fasteners and at seams.
Types of Corrosion

F. Intergranular Corrosion
 An attack on the grain boundaries of a metal.
 A highly magnified cross section of any
commercial alloy shows the granular structure
of the metal.
 It consists of quantities of individual grains,
and each of these tiny grains has a clearly
defined boundary which chemically differs
from the metal within the grain.
 The grain boundary and the grain center can
react with each other as anode and cathode
when in contact with an electrolyte.
Types of Corrosion

G. Exfoliation Corrosion
 An advanced form of intergranular
corrosion and shows itself by lifting up
the surface grains of a metal by the
force of expanding corrosion products
occurring at the grain boundaries just
below the surface.
 It is visible evidence of inter-granular
corrosion and is most often seen on
extruded sections where grain
thickness are usually less than in rolled
forms.
CESSNA 182 RH WING FLAPS
Types of Corrosion

H. Galvanic Corrosion
 Occurs when two dissimilar metals make contact in the presence
of an electrolyte.
 It is usually recognizable by the presence of a build-up of
corrosion at the joint between the metals.
Types of Corrosion

I. Stress Corrosion
 This form of corrosion involves a
constant or cyclic stress, acting in
conjunction with a damaging
chemical environment.
Types of Corrosion

J. Fatigue Corrosion
 Involves cyclic stress and a corrosive
environment
 Metals may withstand cyclic stress for
an infinite number of cycles so long
as the stress is below the endurance
limit of the metal.
Types of Corrosion

K. Fretting Corrosion
 Occur at the interface of two highly-loaded
surfaces which are not supposed to move
against each other.
 Vibration may cause the surfaces to rub
together resulting in an abrasive wear
known as fretting.
 The most common example of fretting
corrosion is the smoking rivet found on
engine cowling and wing skins.
Corrosion treatment

All corrosion products must be removed as soon as they are discovered,

because corrosion continues as long as the deposits remain on the surface.
Regardless of the type of corrosion or the metal involved, corrosion
treatment requires three basic steps:
1.Remove as much of the corrosion as possible.
2.Neutralize any residual material.
3.Restore the protective surface film.
Note:
Corrosion under a paint film cannot be thoroughly inspected without first removing all the paint.
However, before using an unfamiliar paint remover, first test it on a piece of metal similar to that of
the structure to be worked on. One thing to keep in mind is never use a caustic paint remover.
Corrosion treatment

 Prior to applying a paint remover, all areas not to be stripped should be masked with
heavy aluminum foil to keep the stripper from accidently coming into contact with these
areas.
 Water rinseable paint remover having a syrupy consistency is usually best for aircraft
surfaces. This type of remover is applied with a brush by daubing it on the surface rather
than brushing it on.
 Cover the surface with a heavy coating of remover and allow it to stand until the paint
swells and wrinkles up. This breaks the bond between the finish and the metal.
 It may be necessary to reapply the remover. If so, scrape the old paint away with a
plastic or aluminum scraper, and apply the second coat of remover. This allows the
active chemicals to get to the lower layers of finish.
Treatment of Aluminum Alloy

Mechanical Corrosion Removal

After the paint is removed from a corroded area, all traces of corrosion
must be removed from the surface. Very mild corrosion may be removed
by using a neutral household abrasive cleaner, such as Bon-Ami , but be
sure that the abrasive does not contain chlorine. Nylon scrubbers, such( as
"ScotchBrite" pads, can also be used to remove mild corrosion. More severe
corrosion can be removed by brushing with aluminum wool or with an
aluminum wire brush. Under no circumstances should you use a steel wire
brush or steel wool since traces of the steel can become embedded in the
aluminum and lead to severe corrosion.
Treatment of Aluminum Alloy

Chemical Neutralization
After removing all corrosion, treat the surface with a five percent chromic
acid solution to neutralize any remaining corrosion salts. After the acid
has been on the surface for at least five minutes, it should be washed off
with water and allowed to dry. Alodine treatment conforming to MIL-C-
5541 will also neutralize corrosion, as well as form a protective film on the
metal's surface.
Treatment of Aluminum Alloy

Protective Coating
Although some operators prefer a bare aluminum finish to save weight,
most aircraft owners utilize a painted finish. Paint is not only attractive
and distinctive, but also provides additional protection from impact
damage and corrosion.
Treatment of Aluminum Alloy

Protective Coating -Cladding

Pure aluminum is noncorrosive. The disadvantage of using pure aluminum
is that it is not strong enough for aircraft structural components and,
therefore, must be alloyed with other metals.
Aluminum alloys can be protected from corrosion and at the same time
made attractive in appearance by coating them with a layer of pure
aluminum.
Treatment of Aluminum Alloy

Protective Coating –Surface Oxide Film (anodizing)

In areas where cladding is not practical, metallurgists have found other
ways of forming films on metal surfaces that are hard, decorative,
waterproof, and airtight.
Furthermore, these films typically have the added benefit of acting as a
base for paint finishes to adhere to. The process of applying an oxide film
is performed in the factories by an electrolytic process known as
anodizing.
 The anodized aluminum layer is grown by passing a direct current through
an electrolytic solution, with the aluminum object serving as the anode
(the positive electrode). The current releases hydrogen at the cathode(the
negative electrode) and oxygen at the surface of the aluminum anode,
creating a build-up of aluminum oxide.
Treatment of Aluminum Alloy

Protective Coating –Surface Oxide Film (Alodizing)

When small parts are fabricated in the field, or when the protective
anodizing film has been damaged or removed, the part can have a
protective film applied through chemical rather than an electrolytic
process. This process is known as alodizing and uses a chemical that
meets specification MIL-C-5541 and is available under several proprietary
names, such as Alodine1201.
Prior to alodizing a component, all traces of corrosion must be removed.
The surface should then be cleaned with a metal cleaner until it supports
an unbroken water film. In this water break test, any break in the film of
rinse water indicates the presence of wax, grease, or oil on the surface,
and further cleaning must be done.
Treatment of Aluminum Alloy

Protective Coating –Organic Finish

One of the most universally used corrosion control devices for metal
surfaces is a good coat of paint.
Paint adherence is not a problem on porous surfaces, but on smooth
surfaces, such as those found on aluminum, the surface must be prepared
in order for the paint to have a rough surface to which it can adhere.
An aluminum surface is typically roughened with a mild chromic acid
etch, or by the formation of an oxide film through anodizing or alodizing.
Treatment of Aluminum Alloy

Protective Coating –Organic Finish

Zinc chromate primer is an inhibiting primer, meaning that the film is
slightly porous and water can enter it causing chromate ions to be released
and held on the surface of the metal.
This ionized surface prevents electrolytic action and inhibits the formation
of corrosion.
A wash primer is used in aircraft factories for priming new aircraft before
they are painted. This two-part primer consists of a resin and an alcohol-
phosphoric acid catalyst.
Epoxy primers are one of the most popular primers for use under
polyurethane finishes because they provide maximum corrosion protection.
For maximum corrosion protection, they can be applied over a wash primer.
Treatment of Ferrous Metals

Mechanical Corrosion Removal

The most effective method of removing rust is by mechanical means.
Abrasive paper and wire brushes can be used, but the most thorough
means of removing all corrosion from unplated steel parts is by abrasive
blasting.
Abrasive blasting is typically done using sand, aluminum oxide, or glass
beads.
Treatment of Ferrous Metals

Surface Treatment –Chrome Plating

One way to protect ferrous metals from corrosion is through chrome
plating. This plating process produces an airtight coating over the surface
that excludes moisture from the base metal. There are two types of
chrome plating used in aircraft construction: decorative and hard chrome.
Decorative chrome is used primarily for its appearance and surface
protection, while hard chrome is used to form a wear-resistant surface on
piston rods, cylinder walls, and other parts which are subject to abrasion.
Treatment of Ferrous Metals

Surface Treatment –Cadmium Plating

Almost all steel aircraft hardware is cadmium-plated. This soft, silvery-
gray metal is electroplated onto the steel to a minimum thickness of 0.005
inch. It provides an attractive finish as well as protection against
corrosion.
When the cadmium plating on a part is scratched through to the steel,
galvanic action takes place and the cadmium corrodes. The oxides which
form on the surface of the cadmium are similar to those which form on
aluminum in that they are dense, airtight, and watertight. This means that
no further corrosion can take place once the initial film has formed. This
type of protection is known as sacrificial corrosion
Treatment of Ferrous Metals

Surface Treatment –Galvanizing

Steel parts such as firewalls are typically treated with a coating of zinc in
a process called galvanizing. The protection afforded by this process is
similar to that provided by cadmium plating in that when penetrated, the
zinc corrodes and forms an airtight oxide film.
Steel is galvanized by passing it through vats of molten zinc and then
rolling it smooth through a series of rollers.
Treatment of Ferrous Metals

Surface Treatment –Metal Spraying

Aircraft engine cylinders are sometimes protected from corrosion by
spraying molten aluminum on their surface.
To accomplish this process, a steel cylinder barrel is sand-blasted
absolutely clean, then aluminum wire is fed into an acetylene flame where
the wire is melted and blown onto the surface by high-pressure
compressed air.
Corrosion protection afforded by this treatment is sacrificial corrosion,
similar to that provided by cadmium and zinc coating.
Treatment of Ferrous Metals

Surface Treatment –Organic Coatings

The most common organic coating used to protect ferrous metals is paint.
However, like aluminum, the surface must be properly prepared to ensure
a good bond.
Dry abrasive blasting typically removes all of the surface oxides and
roughens the surface enough to provide a good bond for the paint .