TRAINING NOTES

CODE: D-206/011
IIAE Airframe Structure - I
TECHNICAL RESEARCH CELL

METHODS OF SURFACE PROTECTION

Corrosion Protection of Aluminum Alloys

Pure aluminum is relatively corrosion resistant, but when it is alloyed, other elements to
give it strength, it loses this resistance. The easiest way to protect aluminum alloys from
corrosion is to cover their surface.
There are ways to do this: roll a thin coating of pure aluminum on the alloy sheet, a
hard, airtight oxide coating on the surface of the metal; or cover the face with a film of enamel
or lacquer.
Aluminum alloy sheets to be used as the outside skin of an aircraft can be protected
from corrosion and given an attractive finish by rolling a layer of re aluminum on both of their
surfaces. This resulting material is called clad aluminum and is available under such registered
trade names as Alclad and Pureclad. The pure aluminum coating is about 2 to 5% of the
thickness of the alloy sheet, and it decreases the strength of the sheet somewhat.
Pure aluminum cladding does not corrode, but an airtight oxide film forms on its surface
and prevents any oxygen or moisture from reaching metal. The alloy sheet is protected as long
as the cladding is not scratched rough.

Oxide-Film Protection

A hard, airtight oxide film may be deposited on the surface of aluminum alloy sheets by
either an electrolytic or a chemical action. The electrolytically deposited film is called an
anodized film. The chemically deposited film is called a conversion coating, sometimes called
Alodizing after one of the popular chemicals used to form the film, Alodine. These oxide films
not only protect the metal, but provide a slightly rough surface that makes it possible r a paint
film to adhere.

Enamel or Lacquer Coating

Airplanes may be given an attractive and protective finish by covering the metal with a
coating of enamel or lacquer. Before this type of finish will adhere to the metal, the surface
must be prepared, usually with a primer. The most commonly used primers are zinc chromate,
wash primer, and epoxy primer.

Alclad aluminum

A sheet of aluminum alloy that has a coating of pure aluminum rolled on one or both of its
surfaces for corrosion protection.
Alclad. A registered trade name for clad aluminum alloy.
Pureclad. A registered trade name for clad aluminum alloy.
Anodizing. The electrolytic process in which a hard, airtight, oxide film is deposited on
aluminum alloy for corrosion protection.
Alodine: - The process of alodining is the chemical application of a protective chromate
conversion coating upon aluminum. The alodining process provides good corrosion protection,
even when scratched. Paint sticks to its extremely well, in some cases, it can substitute for
 TRAINING NOTES
CODE: D-206/011
IIAE Airframe Structure - I
TECHNICAL RESEARCH CELL

primer. Alodineis a brand name for a process that is generally called chromate conversion
coating. These coating are electrically conductive and corrosion resistant but with almost no
abrasion resistance. The registered trade name for a popular conversion coating chemical
used to produce a hard, airtight, oxide film on aluminum alloy for corrosion protection.
Anodizing
Anodizing is an electrochemical process that converts the surface aluminum into aluminum
oxide. It is non conductive with significant corrosion and abrasion resistance. Both coating are
widely used as adhesion promoters. The final finish must cover the corrosion treatment.
Generally, chromate conversion coating is less expensive than anodizing, while offering better
protection.
A good coat of polyurethane enamel is an acid-proof finish that is far superior to the black
asphaltum paint. When an aircraft is being painted with polyurethane, coat the battery box and
the adjacent area with polyurethane. It will provide protection from the fumes of the lead acid
or nickel-cadmium batteries and will not chip or break away from the metal. Polyurethane will
not wash away with gasoline or any ordinary solvents.