CORROSION

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

CORROSION is a natural occurrence that attacks metal by chemical
or electrochemical action and converts it back to a
metallic compound (oxide for example).
a substance that creates metal corrosion is called
corrosive agents.
the appearance of corrosion varies with various
metals.
aluminum and magnesium – grey or white
copper – green
steel – red

CLASSIFICATION OF CORROSION
Direct Chemical Corrosion
Electrochemical Corrosion

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

 an attack resulting from a direct exposure of a bare
DIRECT surface to caustic liquid or gaseous agents.
CHEMICAL
The most common agents causing direct chemical
CORROSION 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.

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

 Four conditions must exist before electrochemical corrosion
can occur:
ELECTRO 1. A metal subject to corrosion (anode).
2. A dissimilar conductive material (cathode), which has
CHEMICAL fewer tendencies to corrode.
3. Presence of a continuous, conductive liquid path
CORROSION (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).

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

 if there are more or fewer electrons than protons, the atom is
CHARGED said to be charged and is called an ion.
positive ion – more protons
PARTICLE negative ion – more electrons
an ion is unstable, always seeking to lose or gain electrons so it can
change back into a balanced, or neutral, atom.
Electrochemical Series – shows the relative ease with which
metals can ionize
Anodic metal - metal that gives up electrons and corrodes easily
Cathodic metal – metal the don’t easily give up electrons
Example:
An aluminum structure is in contact with moisture having a trace of
hydrochloric acid, a chemical reaction takes place between the
acid and the aluminum to form aluminum chloride and hydrogen.

The hydrogen is released as a gas, and aluminum chloride,

which is a salt, forms as a white powder on the surface of the
metal. This powder is the visible evidence of corrosion.

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 1. Type of metal
Some factors 2. Heat treatment and grain direction
which influence 3. Presence of a dissimilar, less corrodible metal
metal corrosion 4. Anodic and cathodic surface areas
5. Temperature
and the rate of 6. Presence of electrolytes
corrosion are: 7. Availability of oxygen
8. Presence of biological organisms
9. Mechanical stress on the corroding metal
10. Time of exposure to a corrosive environment
11. Lead/graphite pencil marks on aircraft surface
metals

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

 also referred to as Uniform Etch or Uniform Attack Corrosion
UNIFORM the most common form of corrosion and results from a direct
chemical attack on a metal surface and involves only the
SURFACE metal surface.
on a polished surface, this type of corrosion is first seen as a
CORROSION general dulling of the surface, and if allowed to continue, the
surface becomes rough and possibly frosted in appearance.

one of the most destructive and intense forms of corrosion

PITTING likely result of uniform surface corrosion left untreated
In extreme cases, this can eat completely through the metal
CORROSION it is first noticeable as a white or gray powdery deposit,
similar to dust, which blotches the surface.

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 occurs when two dissimilar metals make contact in the
GALVANIC presence of an electrolyte.
it is usually recognizable by the presence of a build-up of
CORROSION corrosion at the joint between the metals.
anodic metal is smaller than cathodic metal – rapid
corrosion
an attack on the grain boundaries of a metal primarily due to
INTERGRANULAR improper heat treatment of the metal
CORROSION comprising of extremely tiny grains, each of these 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.
Heat treated alloys are quenched promptly. If delayed too
long, these metal grains can reach a size that produces
areas of dissimilar metals large enough to form effective
cathodes and anodes so that intergranular corrosion can form.
Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 extreme case of inter-granular corrosion
EXFOLIATION it occurs chiefly in extruded materials where the grain
structure is more laminar (layer-like) than in rolled sheets
CORROSION or castings.
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.
occur at the interface of two highly-loaded surfaces which
FRETTING are not supposed to move against each other.
vibration may cause the surfaces to rub together resulting
CORROSION 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.

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 aka crevice corrosion
corrosion of metals in:
CONCENTRATION metal-to-metal joint
edge of a joint
CELL CORROSION
2 GENERAL TYPES
1. Oxygen concentration cell corrosion – forms in the
closed areas between faying surfaces and where there is a
deficiency of oxygen. Occur on aluminum, magnesium, or
on ferrous metals.
2. Metal ion concentration cell corrosion – forms on the
open surface
3. Active-Passive cell 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.

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

 special form of oxygen concentration cell which occurs on
metal surfaces having an organic coating system.
FILIFORM It is recognized by its characteristic worm-like trace of
corrosion products beneath the paint film.
CORROSION Polyurethane finishes are especially susceptible to
filiform corrosion

occurs when metal is subjected to a tensile stress in the

presence of a corrosive environment
STRESS cracks caused by stress corrosion grow rapidly as the
corrosive attack concentrates at the end of the crack
CORROSION rather than along its sides.
shot-peen the surface to provide a uniform
compressive stress on the surface.

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 Acids
any acid will severely corrode most of the alloys used in
CORROSIVE airframes.
The most destructive are sulfuric acid (battery acid),
AGENTS halogen acids, nitrous oxide compounds, and organic acids
found in the wastes of humans and animals.
Alkalies
not as corrosive as acids.
aluminum and magnesium alloys are exceedingly prone to
corrosive attack by many alkaline solutions unless the
solutions contain a corrosion inhibitor.
Atmosphere
major atmospheric corrosive agents are oxygen and
airborne moisture
may also contain other corrosive gases and
contaminants, particularly industrial and marine
salt spray.
Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 Water
corrosiveness of water depends on the type and quantity of
CORROSIVE dissolved mineral and organic impurities and dissolved
gases in the water.
AGENTS one characteristic of water that makes it corrosive is its
conductivity.
Salts
are the result of a metallic element combining with a
nonmetal. Magnesium is particularly vulnerable to corrosive
attack from an electrolyte formed by salt solutions.
Mercury
attacks aluminum by a chemical reaction known as
amalgamation. In this process, the mercury attacks along
the grain boundaries within the alloy, and in a very short
time completely destroys it.

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019

 Micro-organisms:
1. Bacteria - may be either aerobic or anaerobic.
CORROSIVE Aerobic bacteria - require oxygen to live.
- accelerate corrosion by oxidizing sulfur to produce sulfuric acid.
AGENTS - promote corrosion by depleting the oxygen supply or by releasing
metabolic products.
Anaerobic bacteria - can survive only when free
oxygen is not present.
- metabolism of these bacteria requires them to obtain part of their
sustenance by oxidizing inorganic compounds, such as iron, sulfur,
hydrogen, and carbon monoxide.

2. Fungi - growths of microorganisms that feed on organic

materials. Low humidity slows their growth and may
prevent corrosion damage.
3. Microbial growth - must be removed completely
by hand with a firm non-metallic bristle brush and
water
Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 Exterior Cleaning – use approved cleaning compounds
Hydrogen embrittlement - results when a chemical
CLEANING AND reaction produces hydrogen gas that is absorbed into
a metal which weakens the metal and cause cracking.
CORROSION
Naphta – removes oil and grease; dry cleaning solvent
TREATMENT Aliphatic Naphtha – does not harm rubber and acrylics
Aromatic Naphta – attacks rubber
Soap and Water – for cleaning tires
Varsol/kerosene – exhaust stain cleaner
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.
Mechanical Removal:
Scotch Brite – mild corrosion
Aluminum wool/wire brush – severe corrosion
Sandpaper - 280-grit, then 400-grit
Chemical Neutralization –apply chromic acid (at least 5 mins)
Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 CORROSION Anodizing (surface oxide film)
electrochemical oxidation of an aluminum surface designed
to produce a stable film of aluminum's oxide on its surface.
PROOFING Alodining
TECHNIQUES a non electrolytic chemical treatment intended to provide
corrosion prevention to aluminum products left unpainted,
as well as to improve adhesion of painting processes.
(Aluminum) Cladding
clad with pure aluminum (anodic)
slight pits, scratches, or other defects through the
cladding material must be avoided, since the
aluminum alloy core will corrode rapidly.
Organic Film
zinc chromate primer, wash primer, epoxy primer are
organic coatings commonly used to protect metals.
Shot-peening
The surface can be placed in compression, are
effective in preventing stress corrosion.
Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019
 SURFACE TREATMENT
CORROSION
Nickel or Chrome Plating
PROOFING plating process which produces an airtight coating over the
surface that excludes moisture from the base metal.
TECHNIQUES 2 types of chrome plating:
decorative chrome – appearance and surface protection
(Ferrous Metal) hard chrome – form wear and abrasion resistant surface
Cadmium Plating
almost all steel aircraft is cadmium plated
Galvanizing (zinc coating)
zinc corrodes and forms an airtight oxide film

(Tube Interiors) Linseed Oil – protects the interior surface of sealed

structural steel tubing against corrosion

Prepared by: Engr Derik R De Castro PhilSCA Comprehensive Review 2019