PHILIPPINE STATE COLLEGE OF AERONAUTICS

INSTITUTE OF ENGINEERING AND TECHNOLOGY

AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

LABORATORY
MODULE 02:
Corrosion Control

AE 214
AIRCRAFT MATERIALS,
CONSTRUCTION AND REPAIR

Prepared by:
Engr. Divine Mae L. Magangan
AERONAUTICAL ENGINEERING FACULTY 2020
PhilSCA-InET
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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

TABLE OF CONTENTS
Title Ref. no Page
Introduction I 7
Lab Module Activity 2.1a - 7
Factors Affecting Corrosion I, II, IV 8
General Types of Corrosion I, II, IV 10
Lab Module Activity 2.1b - 11
Forms of Corrosion I, II, IV 12
Common Corrosive Agents I, II, IV 20
Laboratory Activity 2 part 1 III 21
Corrosion Detection on Aircraft I, II, IV 24
Treatment of Corrosion V 27
Laboratory Activity 2 part 2 - 30
Aircraft Cleaning I, II, IV 32
Lab Module Activity 2.2 - 38
Assessment - 39

TIME COMMITMENT FOR THIS MODULE

Reading Materials Time
Introduction 5 minutes
Factors Affecting Corrosion 15 minutes
General Types of Corrosion 15 minutes
Forms of Corrosion 60 minutes
Common Corrosive Agents 10 minutes
Corrosion Detection on Aircraft 60 minutes
Treatment of Corrosion 60 minutes
Aircraft Cleaning 60 minutes
Activities Time
Lab Module Activity 2.1a 10 minutes
Lab Module Activity 2.1b 15 minutes
Lab Module Activity 2.2 30 minutes
Laboratory Activity and Report (Material’s Preparation not included) 727 minutes
Video Materials Time
Treatment of Corrosion – bit.ly/2FPv58B 13 minutes
TOTAL 1080 minutes

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

FIGURES
Figure
References
No.
Fuse School Global Education. (2013, September 12). Corrosion Activity [Illustration].
1 Youtube. https://www.youtube.com/watch?v=T4pSuflO9fk
Federal Aviation Administration. (2018). Direct chemical attack in a battery
2 compartment [Photograph]. In Aviation Maintenance Handbook – General (Chapter 8-
Page 4).
Federal Aviation Maintenance Handbook. (2018). Electrochemical attack. [Diagram].
3 (Chapter 8-Page 5).
Electrochemical Series of Metals. (n.d.). [Chart].
4 http://onelearningsolution.blogspot.com/2015/01/66-electrochemical-series.html
Federal Aviation Administration. (2018b). Surface Corrosion [Photograph]. In Aviation
5
Maintenance Handbook – General (p. Chapter 8-7).
Federal Aviation Administration. (2018b). Filiform corrosion. [Photograph]. In Aviation
6 Maintenance Technician Handbook (p. Chapter 8-8).
Pitting Corrosion. (n.d.). [Photograph]. Auto-Technnology.
7 https://autotechnology.com/news/2020/06/how-do-you-test-for-corrosion/
Federal Aviation Administration. (2018b). Types of Pitting corrosion. [Illustration]. In
8 Aviation Maintenance Technician Handbook (p. Chapter 8-8).
Federal Aviation Administration. (2018b). Dissimilar Metal Corrosion. [Photograph]. In
9
Aviation Maintenance Technician Handbook (p. Chapter 8-8).
Federal Aviation Administration. (2018b). Metal Ion Concentration Cell. [Illustration].
10 In Aviation Maintenance Technician Handbook (p. Chapter 8-8).
Federal Aviation Administration. (2018b). Oxygen Concentration Cell. [Illustration]. In
11 Aviation Maintenance Technician Handbook (p. Chapter 8-8).
Federal Aviation Administration. (2018b). Active-Passive Cells. [Illustration]. In
12 Aviation Maintenance Technician Handbook (p. Chapter 8-9).
Federal Aviation Administration. (2018c). Intergranular corrosion of 7075-T6
13 aluminum adjacent to steel fastener. [Illustration]. In Aviation Maintenance Handbook
(p. Chapter 8-14).
[Intergranular Corrosion]. (n.d.). https://epodreczniki.pl/a/wplyw-oporow-ruchu-na-
14 poruszajace-sie-ciala/Dk02onGEM
Federal Aviation Administration. (2018b). Exfoliation Corrosion [Photograph]. In
15 Aviation Maintenance Handbook – General (p. Chapter 8-15).
Findlay, S., & Harrison, N. (2002, November). Cross-section through the panel
16 showing the exfoliation corrosion. [Photograph]. In Why Aircraft Fail.
Federal Aviation Administration. (2018b). Stress corrosion cracking. [Photograph]. In
17 Aviation Maintenance Handbook – General (p. Chapter 8-10).
Microscopic Stress Corrosion Cracking. (n.d.). [Photograph].
18 https://www.imetllc.com/training-article/stress-corrosion-cracking/
[Concept of Shot Peening]. (n.d.). https://istsurface.com/fr/ressources/sablage-au-
19 jet/martelage-de-surface/
20 Shoot Peening. (n.d.). [Photograph]. https://www.industrialoutpost.com
Han, L., Chen, Y. K., Chrysanthou, A., & O’Sullivan, J. M. (2002, January).
[Micrograph showing fretting marks at the interface between the riveted sheets and a
21 crack running across the two sheets.]. In Self-pierce riveting – A new way for joining
structures.
Prigge, F., Schwack, F., & Byckov, A. (2017, March 23). [Different areas of typical
22 false brinelling and fretting corrosion damage]. In Own work.
Corrosion Fatigue Crack. (n.d.). [Photograph]. https://www.r-
23 techmaterials.com/materials-consultancy/corrosion-fatigue-crack/

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Federal Aviation Administration. (2018b). Galvanic Corrosion. [Photograph]. In
24 Aviation Maintenance Handbook – General (p. Chapter 8-11).
Federal Aviation Administration. (2018b). Corrosion on Metals. [Diagram]. In Aviation
25 Maintenance Handbook – General (p. Chapter 8-7).
Federal Aviation Administration. (2018b). Dissimilar metal contacts that will result in
26 electrolytic corrosion. [Diagram]. In Aviation Maintenance Handbook – General (p.
Chapter 8-21).
Williams, J. (n.d.). Steel Samples [Photograph]. In An Inexpensive Corrosion
27 Laboratory Experiment – Suitable for All Ages.
Williams, J. (n.d.). Three Steel Corrosion Samples after 48 hours immersion (left) and
28 Straight and Bent Nails after 48 hours immersion (right) [Photograph]. In An
Inexpensive Corrosion Laboratory Experiment – Suitable for All Ages.
Federal Aviation Administration. (2018b). Exhaust nozzle area.. [Photograph]. In
29 Aviation Maintenance Handbook – General (p. Chapter 8-12).
Mikkelsen, E. (2017, August 4). Lower Battery Compartment [Photograph]. Youtube.
30 https://www.youtube.com/watch?v=VtzGrdFGGFw
Bilge Areas. (n.d.). [Photograph]. Blogspot. https://parr-
31 agingaircraft.blogspot.com/2014/07/
Federal Aviation Administration. (2018b). The landing gear area should be cleaned and
32 inspected more frequently than other areas. [Photograph]. In Aviation Maintenance
Handbook – General (p. Chapter 8-13).
Water Entrapment Areas. (n.d.). [Photograph]. Public Apps.
33 https://publicapps.caa.co.uk
Engine Inlet Areas and Cooling Vents. (n.d.). [Photograph]. Pinterest.
34 https://i.pinimg.com/originals/bd/f1/87/bdf1871c0f5820bc2b11b978a664f09e.jpg
Wing Flap and Spoiler Access. (n.d.). [Photograph]. Zinfos.
35 https://www.zinfos974.com/Et-si-le-debris-d-aile-retrouve-a-St-Andre-etait-un-
flaperon-d-un-Boeing-777-comme-celui-de-la-Malaysian-Airlines_a88451.html
Aircraft Skin Buckling. (n.d.). [Photograph]. Pinterest.
36 https://www.pinterest.ph/pin/13299761389249258/
Kahn, S. N. (2011, August 9). Helicopter Rotor Head Corrosion Control
[Photograph].Wikimedia.https://commons.wikimedia.org/wiki/File:US_Navy_110809-
37 NZZ999018_Aviation_Machinist%27s_Mate_2nd_Class_Branden_Rucker_performs_c
orrosion_control_on_the_tail_rotor_of_an_SH-60F_Sea_Hawk_he.jpg
Way, B. (2017). Corroded Material Samples [Screenshot]. Youtube.
38 https://www.youtube.com/watch?v=CQMzUkEKaBo&t=57s
Way, B. (2017). Corroded Material Samples, Commercial and Self-Formulated
39 Corrosion Remover [Screenshot]. Youtube.
https://www.youtube.com/watch?v=CQMzUkEKaBo&t=57s
Mechanical removal of rust residue after the corroded material was soaked. (2019).
40 [Screenshot]. Youtube. https://www.youtube.com/watch?v=knAv9q0gIQM
Exterior Wet Wash. (n.d.). [Photograph]. Jet-Clean – Schwechlen. http://jet-clean-
41 eap.com/exterior-wet-wash/
Aircraft Dry Wash. (n.d.). [Photograph]. Dry Green Cleaning.
42 http://www.drygreencleaning.com/planes
Aircraft Polishing. (n.d.). [Photograph]. Quick Fix Aviation.
43 https://quickfixaviation.com/services/paint-surface-polishing/
Aircraft Cabin Cleaning. (n.d.). [Photograph]. Lonely Planet.
44 https://www.lonelyplanet.com/articles/airlines-cleanest-cabins
Powerplant Cleaning. (n.d.). [Photograph]. S7 Technics.
45 https://www.s7technics.ru/en/s7-technics-shares-its-aero-engine-cleaning-
experience-with-airlines/

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

REFERENCES
Reference No.
Federal Aviation Administration. 2018. A&P Technician General Workbook FAA-
H-8083-30A. Jepessen Seanderson Inc. ISBN# 0-88487-212-2.bit.ly/32xo84p
I

Federal Aviation Administration. 2009. Federal Aviation Regulations AC 43.113-

II
1B. bit.ly/3kjHSP3

Williams, J. (2011). Simple Corrosion Experiment in a Freshman Materials

Course [Slides]. Semanticscholar.Org. https://pdfs.semanticscholar.org/961 III
f/4bb85784a44356a26de8e5ac77a344546ad1.pdf
Federal Aviation Administration. (2018). AC 43-4B Corrosion Control for Aircraft
(1st ed., Vol. 1) [E-book]. FAA. IV
https://www.faa.gov/documentLibrary/media/Advisory_Circular/AC_43-4B.pdf
Jim Hein. (2012, May 26). Corrosion 1 Part 3.WMV [Video]. YouTube.
V
https://www.youtube.com/watch?v=cHfRGQdnC04&t=41s

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
The concentration of this laboratory module is on the types of corrosion, corrosion
detection and treatment as well as the general procedures and measures in aircraft
cleaning.

LEARNING OUTCOMES

Program Learning Outcomes [PLO]

PLO 1. Apply knowledge of
mathematics, physical sciences, Course Learning Outcomes [CLO]
engineering sciences to the
practice of aeronautical
engineering. CLO 1. Discuss basic aircraft
Module Learning Outcomes [MLO]
PLO 3. Design, improve, innovate, construction according to functions
and to supervise systems or and types of its parts. MLO 1. Discuss and differentiate
Topic Learning Outcomes
processes to meet desired needs CLO 2. Categorize metallic and types and forms of corrosion in an [TLO]
within realistic constraints. non-metallic materials through their aircraft based on their probable
PLO 4. Function in multi- properties and application to the cause and effects. TLO 9. Devise corrosion protection
disciplinary and multi-cultural teams aircraft structure. MLO 2. Describe the effects of and control to metallic materials
CLO 3. Distinguish standard aircraft corrosion given by different used in aircraft by defining the
PLO 6. Understand the professional
hardware, tools, and substitutes corrosive agents. probable causes, types and
and ethical responsibility
based on their utilization in aircraft MLO 3. Detect corrosion in an detection.
PLO 11. Use techniques, skills, and construction and repair.
modern engineering tools aircraft based on their exposure
necessary for aeronautical CLO 5. Explain the processes, and susceptibility to corrosive TLO 10. Perform corrosion
engineering practice testing, repair and inspection of agents. protection and control by following
aircraft materials based on MLO 4. Classify and demonstrate proper cleaning procedures that
PLO 12. Knowledge and manufacturer and regulatory
understanding of engineering and procedures in treating materials remove built up contamination
requirements. considering their properties. without damaging the materials
management principles as a
CLO 7. Select applicable repair and MLO 5. Classify procedures in used in structural components of an
member and leader in a team, to
prevention methods available for cleaning an aircraft based on their aircraft.
manage projects and in
multidisciplinary environments. aircraft structural damages by exposure and susceptibility to
defining their probable causes and corrosive agents.
types.
MLO 6. Practice safety measures in
CLO 8. Organize the processes, performing corrosion laboratory
testing, and inspection according to activity.
the aircraft's airworthiness
requirements.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

INTRODUCTION

LAB MODULE ACTIVITY 2.1a

Before you proceed to the topic, look at Figure 1.

Fig. 1 Corrosion Activity

(See Figure 1, from left to right) A gold ring, copper tube, iron nail and aluminum toy
are left out in many years.
1) Which object will be in its best condition?
2) Which object will be in its worst condition?
3) What could be the factors for corrosion?

Think about your answers before checking the correct answers here

As an institution of higher learning, students are expected to display highest degree of honesty and professionalism in their
class work, requirements, and activities; thus, in no case that cheating—or any form of it, may it be plagiarism, copying
other students' works, and fabrication of materials—shall be tolerated. The Philippine State College of Aeronautics
assumes as a simple and minimal preferred of habits in academic matters that students be truthful and that they publish for
deposit solely the merchandise of their personal efforts.

All aircraft construction and components contain metal. The parts often exposed
to air and different types of liquid are susceptible to corrosion. Corrosion is defined
as a natural phenomenon which attacks metal by chemical or electrochemical action
and converts it into a metallic compound, such as an oxide, hydroxide, or sulfate. The
corrosion occurs because metals tend to return to their natural state. (Federal
Aviation Administration, 2018).

It is required for an aircraft to be regularly inspected and cleaned to control

corrosion that may leave damage. Dirt and grease are visually unpleasant and can
also accelerate corrosion formation by trapping moisture and corrosive materials
between aircraft structures. You must be able to define the forms of corrosion, its
probable causes and detect parts of the aircraft susceptible to corrosion. Awareness
of proper cleaning procedures and detection is needed to remove the build-up of

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
contamination in structural components without damaging its materials. If the
corrosion effects have become established, you must also select appropriate
methods to minimize and control these.

Laboratory Module key points:

a. Factors Affecting Corrosion
b. General Types of Corrosion
i. Direct Chemical Attack
ii. Electrochemical Corrosion
c. Forms of Corrosion
i. Oxidation/Dry Corrosion
ii. Wet Corrosion
iii. Uniform Surface Corrosion
iv. Galvanic Corrosion
v. Pitting Corrosion
vi. Concentration Cell Corrosion
vii. Filiform Corrosion
viii. Intergranular Corrosion
ix. Exfoliation Corrosion
x. Stress Corrosion
xi. Fretting Corrosion
d. Common Corrosive Agents
e. Corrosion Detection in Aircraft
f. Treatment of Corrosion
g. Aircraft Cleaning

FACTORS AFFECTING CORROSION

The following are some of the factors that influence metal corrosion and rate of
corrosion:
1) Type of metal
2) Heat treatment and grain direction
3) Presence of a dissimilar, less corrodible metal (galvanic corrosion)
4) Anode and cathode surface areas (in galvanic corrosion)
5) Temperature
6) Presence of electrolytes (such as hard water, salt water, or battery fluids)
7) Availability of oxygen
8) Presence of different concentrations of the same electrolyte
9) Presence of biological organisms
10) Mechanical stress on the corroding metal
11) Time of exposure to a corrosive environment; and
12) Lavatory fluids with hard water, salt water, or battery fluids

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
PURE METALS
Pure metals are combined with other metals to form alloy because it is not suitable
alone for aircraft construction. Corrosion can occur on the grain boundaries of alloy
materials. However, metals have a wide range of corrosion resistance. The most noble
metals, does not lose electrons easily thus do not corrode easily, are gold and silver.
While magnesium and aluminum are the most active metals, they lose electrons easily
thus corrode easily.
CLIMATE
The environmental conditions of where an aircraft is operated and maintained can
significantly affect the corrosion characteristics. It is harmful to an aircraft to be
operated in a hot and moist climate because an electrochemical attack would likely
increase rather than in a dry climate.
GEOGRAPHICAL LOCATION
These include flight routes and bases of operation that expose aircraft to more
corrosive conditions than others. The corrosion severity of any area may be increased
by many factors, including airborne industrial pollutants, chemicals used on runways
and taxiways to prevent ice formation, humidity, temperatures, prevailing winds from
a corrosive environment, etc.
FOREIGN MATERIAL
The following are controllable factors that can affect the spread of corrosive attack
caused by foreign materials to metal surfaces.
• Soil and atmospheric dust
• Oil, grease, and engine exhaust residue
• Salt water and salt moisture condensation
• Spilled battery acids and caustic cleaning solutions
• Welding and brazing flux residues

MICRO-ORGANISMS
Slimes, molds, fungi and other living organisms (some microscopic) can grow on damp
surfaces. If the damp surfaces were not cleaned and treated, there is a possibility that
corrosion in the area will occur.
MANUFACTURING PROCESSES
Manufacturing processes, such as machining, forming, welding, or heat treatment, can
leave stresses in aircraft parts. The residual stress can cause cracking in a corrosive
environment when the threshold for stress corrosion is exceeded.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
GENERAL TYPES OF CORROSION

Corrosion is a natural phenomenon which attacks metal by chemical or electrochemical action

and converts it into a metallic compound, such as an oxide, hydroxide, or sulfate. Substances
that cause corrosion are called corrosive agents. Water or water vapor containing salt combine
with oxygen in the atmosphere to produce the most prominent corrosive agents. Additional
corrosive agents include acids, alkalis, and salts.

The corrosion process involves two simultaneous changes: the metal that is attacked
or oxidized suffers what is called anodic change, and the corrosive agent is reduced
and is considered as undergoing cathodic change.
Direct Chemical Corrosion
Direct chemical attack or pure chemical
corrosion results from 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. Fig. 2 Direct Chemical Attack

Electrochemical Corrosion

REVIEW: When the number of

electrons matches the number
of protons in an atom, the atom
is said to be electrically
balanced. However, if there are
more or fewer electrons than
protons, the atom is said to be
charged and is called an ion. If
there are more electrons than
protons, it is a negative ion, but
if there are more protons than
electrons, it is a positive ion. An
ion is unstable, always seeking
to lose or gain electrons so it can
change back into a balanced, or
neutral, atom

Fig. 2 Electro-Chemical Attack

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

Fig. 4 Electrochemical Series of Metals

The earlier a metal appears in the series, the more easily it gives up electrons. In other
words, a metal that gives up electrons is known as an anodic metal and corrodes
easily. On the other hand, metals that appear later in the series do not give up
electrons easily and are called cathodic metals.

LAB MODULE ACTIVITY 2.1b

Look back on the objects observed in the Introduction (or click here). Rank the objects
based on which will be corroded first and write the type of metal of each object based
on the Electrochemical series chart. Follow the table formatted below.

Rank Object Type of Metal based on the Electrochemical Series

1st

2nd

3rd

4th

As an institution of higher learning, students are expected to display highest degree of honesty and professionalism in their
class work, requirements, and activities; thus, in no case that cheating—or any form of it, may it be plagiarism, copying
other students' works, and fabrication of materials—shall be tolerated. The Philippine State College of Aeronautics
assumes as a simple and minimal preferred of habits in academic matters that students be truthful and that they publish for
deposit solely the merchandise of their personal efforts.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Many metals become ionized due to galvanic action when brought into contact with
dilute acids, salts, or alkalis, such as those found in industrially contaminated air.
Corrosion is an electrochemical action in which one metal is changed into a chemical
salt. When two dissimilar metals are in contact with each other in the presence of some
electrolyte such as hydrochloric acid or plain water, the less active metal acts as the
cathode and attracts electrons from the anode. As the electrons are pulled away from
the anode the metal corrodes.

One of the basic characteristics of metals is their electrode potential. In other words,
when two dissimilar metals are placed in an electrolyte, an electrical potential exists.
This potential forces electrons in the more negative material, the anode, to flow to the
less negative material, the cathode, when a conductive path is provided. As discussed
earlier, corrosion occurs when electrons leave an element.

The following four conditions must exist before electrochemical corrosion can occur
1. Presence of a metal that will corrode (anode).
2. Presence of a dissimilar conductive material (cathode) which has less tendency
to corrode.
3. Presence of a conductive liquid (electrolyte).
4. Electrical contact between the anode and cathode (usually metal-to-metal
contact, or a fastener).

Corrosion control, therefore, consists of preventing the chemical action by eliminating

one or more of these basic requirements.

FORMS OF CORROSION

Surface Corrosion

Damage Rating:
Cause:
o Direct chemical attack
o Electro-chemical attack
Effect:
o general roughening, etching, or pitting of
the surface of a metal, frequently
accompanied by a powdery deposit of
corrosion products.
o In closer inspection, paint or plating is
lifted off the surface in small blisters that
result from the pressure of the underlying
accumulation of corrosion products.
Detection:
o Metal surfaces
Other Information:
o It is called as uniform etch or uniform Fig. 5 Surface Corrosion
attack corrosion.
o It is the most common form of corrosion.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Filiform Corrosion

Damage Rating:
Cause:
o Polyurethane finishes
o Between 78–90 percent relative humidity
of the air.
o Surface is slightly acidic.
Effect:
o Worm-like trace of corrosion products
beneath the paint film.
o Can lead to intergranular corrosion
Fig. 6 Filiform corrosion.
Detection
o Beneath paint film
o Steel and aluminum surfaces.
Removal:
o Glass bead blasting material with portable
abrasive blasting equipment or sanding.
Prevention/Control:
o Storing aircraft in an environment with a
relative humidity below 70 percent
o Using coating systems having a low rate
of diffusion for oxygen and water vapors
o Washing the aircraft to remove acidic
contaminants from the surface, such as
those created by pollutants in the air.

Pitting Corrosion

Damage Rating:
Cause:
o Metals that form protective oxide films.
Effect:
o White or gray powdery deposit, similar to
dust, which blotches the surface. Fig.7 Pitting Corrosion
o Tiny holes or pits can be seen in the
surface.
Detection:
o Aluminum and magnesium alloys.
Other Information:
o Most destructive and intense form of
corrosion.

Fig.8 Types of Pitting Corrosion

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Dissimilar Metal Corrosion

Damage Rating:
Cause:
o contact between dissimilar metal parts in
the presence of a conductor.
o improper use of steel cleaning products,
such as steel wool or a steel wire brush on
aluminum or magnesium, can force small
pieces of steel into the metal being
cleaned.
Effect:
o Extensive pitting damage.
Detection:
o Points or areas of contact where the
insulation between the surfaces has Fig.9 Dissimilar Metal Corrosion
broken down or been omitted.
o Electrochemical attack is taking place out
of sight.
Prevention/Control:
o Disassembly and Inspection.
o Carefully monitor the use of nonwoven
abrasive pads, so that pads used on one
type of metal are not used again on a
different metal surface.
Concentration Cell Corrosion / Crevice
Corrosion
* 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
I. Metal Ion Concentration Cell
Damage Rating:
Cause:
o Solution may consist of water and ions of
the metal that are in contact with water.
Effect: Fig. 10 Metal Ion Concentration Cell
o An electrical potential exists between the
two points: the area of the metal in contact
with the low concentration of metal ions is
anodic and corrodes; the area in contact
with the high metal ion concentration is
cathodic and does not show signs of
corrosion.
Detection:
o High concentration of metal ions normally
exists under faying surfaces where the
solution is stagnant and a low concentration
of metal ions exist adjacent to the crevice,
created by the faying surface. [Figure 10]
II. Oxygen Concentration Cell Fig. 11 Oxygen Concentration Cell
Damage Rating:
Cause:
o Solution in contact with the metal surface

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
normally contains dissolved oxygen.
Effect:
o Difference in oxygen concentration
between two points.
o Corrosion around low oxygen concentration
areas (anode).
Detection:
o Develop at any point where the oxygen in
the air is not allowed to diffuse into the
solution, thereby creating a difference in
oxygen concentration between two points.
[Figure 11] Fig. 12 Active-Passive Cell
o Under gaskets, wood, rubber, and other
materials in contact with the metal surface
commonly alloys such as stainless steel.

III. Active-Passive Cell

Damage Rating:
Cause:
o Metals that depend on a tightly adhering
passive film, usually an oxide for corrosion
protection.
o Starts as an oxygen concentration cell.
o Passive film is broken beneath the dirt
particle exposing the active metal to
corrosive attack. [Figure 12]
Effect:
o Electrical potential will develop between the
large area of the passive film and the small
area of the active metal.
o Rapid Pitting
Detection:
o Beneath the dirt particle.
Intergranular Corrosion

Damage Rating:
Cause:
o Changes that occur in the alloy during the
heating and cooling process of the
material’s manufacturing.
o Corrosive Environment
Effect: Fig. 13 Intergranular corrosion of 7075-T6 aluminum
o Attack along the grain boundaries of an adjacent to steel fastener
alloy and commonly results from a lack of
uniformity in the alloy structure.
Detection:
o May exist without visible surface evidence
Other Information:
o High strength aluminum alloys and some
stainless steels are particularly susceptible
to this form of electrochemical attack.

Fig. 14 Intergranular Corrosion

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

Exfoliation Corrosion

Damage Rating:
Cause:
o Extruded sections such as spars where
grain thickness is usually less than in
rolled forms.
Fig. 15 Exfoliation Corrosion
Effect:
o Lifting up the surface grains of a metal by
the force of expanding corrosion products
occurring at the grain boundaries just
below the surface.
Detection:
o Difficult to detect in its initial stage.
o Through ultrasonic and eddy current
inspection.
Other Information:
o Advanced form of Intergranular Corrosion.
Fig. 16 Cross-section through the panel showing
the exfoliation corrosion
Stress-Corrosion/Cracking

Damage Rating:
Cause:
o Constant or cyclic stress acting in
conjunction with a damaging chemical
environment.
o Internal or external loading.
o Internal stress may be trapped in a part of
structure during manufacturing processes, Fig. 17 Stress Corrosion Cracking
such as cold working or by unequal
cooling from high temperatures.
o Externally introduced in part structure by
riveting, welding, bolting, clamping, press
fit, etc.
o Specific environments that promotes
stress to certain alloys.
- High strength heat treated
aluminum alloys: Salt solution
and seawater.
- Titanium Alloys: Methyl alcohol-
hydrochloric acid solutions. Fig. 18 Microscopic Stress Corrosion
Cracking.
- Magnesium Alloys: Moist air
o Level of stress that varies from point to
point within the metal.

Effect:
o Cracking
o Structural Failure
Detection:
o Difficult to recognize/detect.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Prevention/Control:
o Applying protective coatings
o Stress relief heat treatments
o Using corrosion inhibitors
o Controlling the environment
o Shot peening – a metal surface increases
resistance to stress corrosion cracking by
creating compressive stresses on the
surface which should be overcome by
applied tensile stress before the surface
Fig 20.
sees any tension load. Therefore, the Fig. 19
Shoot Peening.
Concept of Shot Peening
threshold stress level is increased.

Fretting Corrosion

Damage Rating:
Cause:
o Two mating surfaces, normally at rest with
respect to one another, are subject to
slight relative motion.
o Presence of water vapor.
Effect:
o Pitting of the surfaces and the generation
of considerable quantities of finely divided
debris. Fig. 21 Micrograph showing fretting marks at the
o Localized abrasion occurs. interface between the riveted sheets and a crack
o If the contact areas are small and sharp, running across the two sheets.
deep grooves resembling Brinell
markings or pressure indentations may
be worn in the rubbing surface. This type
of corrosion on bearing surfaces has also
been called false brinelling.
Detection:
o Smoking rivet black (ring around the rivet)
found on engine cowling and wing skins.
Other Information:
o Reaction that is not driven by an
electrolyte, and in fact, moisture may Fig. 22 Different areas of typical false brinelling and
inhibit the reaction. fretting corrosion damage

Fatigue Corrosion

Damage Rating:
Cause:
o Involves cyclic stress and a corrosive
environment.
o Metals may withstand cyclic stress for an
infinite number of cycles so long as the
stress is below the endurance limit of the
metal. Once the limit has been exceeded,
the metal eventually cracks and fails from Fig. 23 Corrosion Fatigue Crack
metal fatigue.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Effect:
o First stage – pitting and crack formations
to such a degree that fracture by cyclic
stress occurs.
o Second stage – essentially a fatigue
stage where failure proceeds by
propagation of the crack (often from a
corrosion pit or pits).
Detection:
o Metal crack and fractures
Other Information:
o Fracture of a metal part due to fatigue
corrosion generally occurs at a stress
level far below the fatigue limit of an
uncorroded part, even though the amount
of corrosion is relatively small.
o Principal difference between these two
types of environment enhanced cracking
is in the character of loading, which is
static in stress corrosion cracking and
alternating/repeated/cycling/periodically
fluctuating in corrosion fatigue.
Galvanic Corrosion
Damage Rating:
Cause:
o Two dissimilar metals make electrical
contact in the presence of an electrolyte.
Effect:
o The rate which corrosion occurs depends
on the difference in the activities. The
greater the difference in activity, the faster
corrosion occurs.
Detection:
o If the surface area of the corroding metal
is smaller than the surface area of the
less active metal, corrosion is rapid and Fig. 24 Galvanic Corrosion
severe.
o When the corroding metal is larger than
the less active metal, corrosion is slow
and superficial.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Figure 25 shows the type of attack and appearance of corrosion in the following
metals.

Fig. 25 Corrosion on Metals

Fig. 26 Dissimilar metal contacts that will result in

electrolytic corrosion.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
COMMON CORROSIVE AGENTS
Corrosive agents are substances that can cause a corrosive reaction. Most corrosive
agents fall into one of two categories, acids, and alkalis. However, care must be taken
not to overlook other less obvious corrosive agents such as the atmosphere which
contains moisture, salts, or corrosive industrial agents.

Corrosive Agents Corrosion Prone Materials

Acids
o Sulfuric acid (battery acid)
o Halogen acids (hydrochloric,
hydrofluoric, and hydrobromic) most of the alloys used in airframes
o Nitrous oxide compounds
o Organic acids found in the wastes
of humans and animals.
Alkalis
o washing soda Aluminum and magnesium alloys ( unless the
o potash (wood ashes) solution contains corrosion inhibitor )
o lime (cement dust).
Salts
o Salt solutions Aluminum alloy, magnesium alloys, and other steels
(except from stainless steel alloys)

Atmosphere
o Oxygen
o Airborne moisture
o Corrosive gases and contaminant Ferrous alloys
particularly industrial and marine
salt spray.
Water
o Type and quantity of dissolved
mineral
o Organic impurities
o Dissolved gasses (particularly
oxygen) in the water.
o Physical factors, such as water
temperature and velocity

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
LABORATORY ACTIVITY 2 Part 1
Title: Corrosion Production and Removal

Output:

VIDEO
1. Create an at least 3-minute video of your observations during the laboratory
activity. Please see the rubrics for this activity at the Assessment Chapter
of this Laboratory Module.
2. Upload your videos on your YouTube Channel and categorized it as ‘unlisted’.
3. The title of your video must follow the format:
‘SURNAME_AE214Corrosion Production and RemovalPart1’
4. Kindly wait for your instructor’s Google form regarding the submission of the
YouTube Links.
Materials:

✓ Candidate Corrosion Materials

(choose one and prepare three
samples)
- Aluminum strip, 1100 series
- Aluminum strip, 6061 series
- Pure copper strip or tube
- Zinc plated hardware, such as an “S”
hook
- Hot-dipped zinc coated roofing nail
- Cadmium coated bolts or screws
- Stainless steel bolt
- Common steel nails
Fig. 27 Steel Samples

✓ Corrodents
- Tap Water
- Household bleach diluted with tap water in the ratio of 100:1
- Calcium chloride solution (like rock salt mixed in water)
✓ Glass/Plastic Jars for each sample
✓ Nylon
✓ Safety Gloves (Synthetic Rubber, Nitrile)
✓ Mask
Procedures:

1. A. Preparation for Metal Strips

For strip testing, 1-inch wide strips about 0.065 inch thick should be used.
These strips should have been sheared into tensile test specimens, then cut in
half. A hole must be drilled in the half-inch width section for a support string.
B. Preparation for Hardware Sample
String may need to be tied to the object to adequately support the material
inside the jar. Bend hardware if needed.
2. Filling the Glass Jars with corrodents

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Wear safety gloves face mask. These are protection from the harmful effects of
household bleach. Fill the glass jars with the right amount of corrodent where
the sample would be fully immersed.
3. Placing the samples in the Glass Jars
Insert the piece of nylon fish line into the hole and used to suspend the
specimen in the jar. The lid should be placed over the jar and the string and
gently tightened, just enough to hold the sample and string. Do not fully tighten
the lid since it may cut the nylon line. In addition, is acceptable to use clear
plastic film over the top of the jar, held in place by a rubber band. A good cover
is needed to prevent evaporation of the corrodent liquid over time.

4. Data and Observations

You will be given a data sheet to use for observations. Observe the samples
about one hour after they are immersed in the corrodent and observe it every
class day until about two or three days.

Fig. 28 Three Steel Corrosion Samples after 48 hours immersion (left) and Straight and
Bent Nails after 48 hours immersion (right)

As an institution of higher learning, students are expected to display highest degree of honesty and professionalism in their
class work, requirements, and activities; thus, in no case that cheating—or any form of it, may it be plagiarism, copying
other students' works, and fabrication of materials—shall be tolerated. The Philippine State College of Aeronautics
assumes as a simple and minimal preferred of habits in academic matters that students be truthful and that they publish for
deposit solely the merchandise of their personal efforts.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Data and Observations

Write your observations in the test specimen after it is immersed in the corrodent
after an hour and every class day until about two or three days.

DATE TIME OBSERVATIONS

(After an hour)

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
CORROSION DETECTION ON AIRCRAFT

Detection Methods
To aid in the detection of corrosion you should use every inspection aid that is available
to you. For example, the complex structure of modern aircraft makes the use of
magnifying glasses, mirrors, borescopes, fiber optics, and other optical inspection tools
imperative for a good visual inspection.
Stress corrosion cracks are sometimes difficult, if not impossible, to detect by visual
inspection alone. Another means of corrosion detection is using ultrasonic equipment.
There are two types of ultrasonic indications used for corrosion detection: the pulse-
echo and the resonance method.
Like ultrasonic inspection, radiological inspection such as x-ray is used to determine if
there is any corrosion on the inside of a structure. However, x-ray inspection requires
extensive training and experience for proper interpretation of the results. Furthermore,
the use of x-ray involves some danger because exposure to the radiation energy used
in this process can cause burns, damage to the blood, and possibly death.

Aircraft Corrosion Prone Areas

The following are the corrosion problem areas common to all aircraft. These areas
should be cleaned, inspected, and treated more frequently than less corrosion prone
areas. This information is not necessarily complete and may be amplified and
expanded to cover the special characteristics of the particular aircraft model involved
by referring to the applicable maintenance manual.

Exhaust Trail Areas

➢ Engine exhaust is corrosive
➢ Trouble Areas
✓ Gaps, seams, hinges, fairings
✓ Areas not reached by cleaning
✓ Rivet heads, skin lap joint, crevices
➢ Inspect by removing and inspecting:
✓ Fairings
✓ Access plates
✓ Empennage (tail assembly) surfaces

Fig. 29 Exhaust nozzle area.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

Battery Compartments and Vent Openings

➢ Electrolyte fumes are hard to contain
➢ Inspect battery compartment and vent opening
➢ Minimize corrosion:
✓ Regular cleaning
✓ Neutralization of acid deposits

Fig. 30 Lower Battery Compartment

Bilge Areas
➢ Sump for collecting waste liquids
✓ Hydraulic fluids
✓ Water
✓ Residual Oil
✓ Dirt and debris
➢ Protection from Corrosion
✓ Chemical conversion coatings
✓ Lap joint sealants
✓ Paint application interior
➢ Inspection focus
✓ Areas under galleys
✓ Areas under lavatories
➢ Maintenance Fig. 31 Bilge Areas
✓ Clean and paint affected areas

Wheel Well and Landing Gear

➢ Vulnerable to corrosion because water, gravel, debris
➢ Corrosion prevention challenge
✓ Paint film coverage difficult to attain
✓ Partial preservative masks corrosion
➢ Heat from braking precludes some preservatives
➢ Common trouble spots
✓ Magnesium wheels
✓ Exposed rigid tubing
✓ Exposed indicator switches
✓ Crevices
Fig. 32 The landing gear area should be
cleaned and inspected more frequently than
other areas.
Water Entrapment Areas
➢ Aircraft designed with drains
➢ Daily inspection standard requirement
➢ Neglected drains may accumulate
✓ Debris
✓ Grease
✓ Sealant

Fig. 33 Water Entrapment Areas

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

Engine Frontal Areas and Cooling Vents

➢ Runways and rain erode protective finish
✓ Dirt
✓ Dust
✓ Gravel
➢ Inspection
✓ Cooling air path
✓ Areas of salt deposits
➢ Maintenance to prevent corrosion
✓ Paint touchups
✓ Hard film preservative coatings Fig. 34 Engine Inlet Areas and Cooling
Vents

Wing Flap and Spoiler Access

➢ Potential for corrosion
✓ Dirt and water collect often undetected
✓ Spoiler and flaps retracted
✓ Inspect with spoilers and flaps deployed.

Fig. 35. Wing Flap and Spoiler Access

External Skin Areas
➢ Consistent maintenance prevents corrosion
➢ Trimming, drilling, riveting destroys finish
➢ Inspection should include edges, fasteners, and missing paint
➢ Piano hinges corrosion prone
✓ Dissimilar metal
✓ Trap dirt, salt, and water
✓ Include lubrication when inspecting
➢ Spot welded areas
✓ Corrosive agents trapped between metal layers.
✓ Corrosion appears at entry point.
✓ Skin buckles with advanced corrosive attack. Fig. 36. Aircraft Skin Buckling
✓ Detect by sighting along welding seam or using a straightedge
➢ Preventive Maintenance
✓ Moisture entry points caused by broken spot welds
✓ Identify and fill with sealant or preservative compound
✓
Miscellaneous Trouble Areas
➢ Helicopter rotor heads
✓ Exposed to elements
✓ Bare steel surface
✓ External working parts
✓ Dissimilar metals contacts
➢ Steel control cables
✓ Check for external corrosion
✓ Check for internal corrosion
✓ Remove external corrosion
o Non-woven abrasive pad soaked in oil
o Steel wire brush
Fig. 37. Helicopter Rotor Head Corrosion Control
o Recoat with Preservative

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

TREATMENT OF CORROSION
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.
Click the image or copy the link below for the discussion of basic procedures in treating corrosion.

bit.ly/2FPv58

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

Metal/Corrosion
Removal Treatment
Product
Mechanical Removal
o Except on highly stressed steel surfaces, the
following can be use
✓ abrasive papers and compounds
✓ small power buffers and buffing
compounds,
✓ hand wire brushing, or steel wool
o Residual rust must be considered
since it usually remains in the bottom
Iron Rust
of small pits and other crevices.
Chemical Removal
o A variety of commercial products that
actively remove the iron oxide without
chemically etching the base metal are
available and can be considered for use.
o The steel part is removed from the airframe
for treatment, as it can be nearly impossible to
remove all residue.
Highly Stressed Steel Parts Chemical Surface Treatment of Steel
o For Highly stresses steel parts, careful o Approved methods for converting active
removal of corrosion products is required rust to phosphates and other protective
because overheating can cause sudden coatings.
failire. The following can be use: o Rinsing and neutralizing of residual acid.
✓ mild abrasive papers, such as o Use of chemical inhibitors on installed
rouge or fine grit aluminum oxide steel parts is not only undesirable, but
or fine buffing compounds on cloth also extremely dangerous.
buffing wheels. Must be always reminded the danger of
Steel ✓ Nonwoven abrasive pads. It is entrapment of corrosive solutions.
essential that steel surfaces are
not overheated during buffing.
o After careful removal of surface corrosion,
reapply protective paint finishes
immediately.
Use of chemical corrosion removers is prohibited
with engineering authorization, because high-
strength steel parts are subject to hydrogen
embrittlement.
Unpainted Aluminum Surfaces
o Care must be taken to prevent staining and o A thin coating of relatively pure
marring of the exposed aluminum. aluminum is applied over the base
o Avoid unnecessary mechanical removal of aluminum alloy. The protection obtained
the protective Alclad layer and the exposure is good and the pure-aluminum clad
of the more susceptible aluminum alloy base surface, commonly called “Alclad,” can
material. be maintained in a polished condition.
Aluminum and The thickness of the outer cladding layer
Aluminum Alloys typically varies between 1% and 15% of
the total thickness.
Anodized Surfaces
o Nonwoven abrasive pads are used for o Anodizing is a common surface
cleaning corroded anodized surfaces. Do treatment of aluminum alloys. Chromic
not use steel wool or steel wire brushes. Do acid and other inhibitive treatments can
not use severe abrasive materials. be used to restore the oxide film.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Intergranular Corrosion in Heat-Treated Aluminum Alloy Surfaces
o The mechanical removal of all corrosion o Any loss of structural strength must be
products and visible delaminated metal evaluated prior to repair or replacement
layers must be accomplished to determine of the part. If the manufacturer’s limits
the extent of the destruction and to evaluate do not adequately address the damage,
the remaining structural strength of the a designated engineering
component. representative (DER) can be brought in
to assess the damage.
Wrought Magnesium Sheet and Forgings
o Limit such mechanical cleaning to the use of
stiff, hog bristle brushes and similar
nonmetallic cleaning tools (including
nonwoven abrasive pads), particularly if
treatment is to be performed under field
conditions.
o .
Installed Magnesium Castings
Magnesium Alloys
o If extensive removal of corrosion products
from a structural casting is involved, a
o Earliest practicable treatment is
decision from the manufacturer may be
required if dangerous corrosive
necessary to evaluate the adequacy of
penetration is to be avoided. Separate
structural strength remaining. Specific
parting surfaces to effectively treat the
structural repair manuals usually include
existing attack and prevent its further
dimensional tolerance limits for critical
progress.
structural members and must be referred to
if any question of safety is involved
o The surface is treated following cleaning
o Use of steel wool, iron scrapers, or steel with a suitable solution of sodium
Titanium and its Alloys brushes for cleaning or for the removal of dichromate. Wipe the treated surface
corrosion from titanium parts is prohibited. with dry cloths to remove excess
solution, but do not use a water rinse.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
LABORATORY ACTIVITY 2 Part 2
Title: Corrosion Production and Removal

Output:

VIDEO
1. Create an at least 3-minute video of your observations and answers to guide
questions during the laboratory activity. Please see the rubrics for this
activity at the Assessment Chapter of this Laboratory Module.
2. Upload your videos on your YouTube Channel and categorized it as ‘unlisted’.
3. The title of your video must follow the format:
‘SURNAME_AE214Corrosion Production and RemovalPart2’
4. Kindly wait for your instructor’s Google form regarding the submission of the
YouTube Links.

Materials:
✓ Corroded Material (any type of
metal and prepare two samples)
✓ Commercial Corrosion Remover
✓ Self-formulated Corrosion
Remover (Own Recipe)
✓ Tub (make sure the sample fits)
✓ Mechanical Corrosion Remover
(Steel brush/abrasive pads, steel
wool etc.) Fig. 38. Corroded Material Samples
✓ Safety Gloves (Synthetic rubber, Nitrile)
✓ Face mask and shield
Procedure:
1. Wear safety gloves, face mask and shield to protect yourself from the
harmful effects of exposure to chemicals in this activity.
2. Create enough amount of your own Corrosion Remover. Use available
ingredients at home.
3. Pour corrosion removers in separate tub. Consider the amount where the
sample would be fully immersed.
4. Soak each sample in the solutions.
5. You will be given a data sheet to use for observations. Observe the samples
about one hour after they are immersed in the solutions and remove the
sample after 24 hours.
6. Remove remaining corrosion in the sample then record your observations.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

Fig. 39. Corroded Material Samples, Commercial Fig. 40. Mechanical removal of rust residue after
and Self-Formulated Corrosion Remover the corroded material was soaked

As an institution of higher learning, students are expected to display highest degree of honesty and professionalism in their
class work, requirements, and activities; thus, in no case that cheating—or any form of it, may it be plagiarism, copying
other students' works, and fabrication of materials—shall be tolerated. The Philippine State College of Aeronautics
assumes as a simple and minimal preferred of habits in academic matters that students be truthful and that they publish for
deposit solely the merchandise of their personal efforts.

Data and Observations

Date Time OBSERVATIONS

(After an hour)

After 24 Hours
Mechanical Removal
of remaining
corrosion.

Guide Questions for the Conclusion

1. What factors contributed to the formation of corrosion in the test specimen?
2. Explain why is it important to follow standard procedures in removing
corrosion?
3. Why corrosion should be given attention in an aircraft structure?

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
AIRCRAFT CLEANING
Aircraft Cleaners and Cleaning Materials
Cleaner and
Cleaning Purpose
Materials
SOLVENT o Used in aircraft cleaning
Dry Cleaning Solvent
o Stoddard solvent is the most common
petroleum base solvent used in aircraft
cleaning.
o Dry cleaning solvent is preferable to
kerosene for all cleaning purposes, but
like kerosene, it leaves a slight residue
upon evaporation that may interfere
with the application of some final paint
films.
Aliphatic and Aromatic Naphtha
o Aliphatic naphtha used for cleaning
acrylics and rubber. Recommended for
wipe down of cleaned surfaces just
before painting.
Safety Solvent
o Trichloroethane (methyl chloroform) is
used for general cleaning and grease
removal.
o Nonflammable
o Replacement for carbon tetrachloride
Methyl Ethyl Ketone (MEK)
o Solvent cleaner for metal surfaces and
paint stripper for small areas
Kerosene
o Softening heavy preservative coatings
o General solvent cleaning, but its use
must be followed by a coating or rinse
with some other type of protective
agent.
Requirement/Precautions
✓ Flashpoint of not less than 105 °F if
explosion proofing of equipment and
other special precautions are to be
avoided.
✓ Safety precautions must be observed
in their use. Particular attention must
be paid to recommended protective
measures including gloves, respirators,
and face shields.
✓ Use of carbon tetrachloride is to be
avoided.
✓ Flashpoint is slightly above 105 °F and
can be used to remove grease, oils, or
light soils.
✓ Aliphatic naphtha flashes at
approximately 80 °F and must be used
with care.
✓ Aromatic naphtha is toxic, attacks
acrylics and rubber products, and must
be used with adequate controls.
✓ The use and safety precautions
necessary when using chlorinated
solvents must be observed. Prolonged
use can cause dermatitis on some
persons.
✓ A highly active solvent and metal
cleaner with a flashpoint of about 24
°F.
✓ Toxic when inhaled, and safety
precautions must be observed during
its use.
✓ Generally leaves an appreciable film
on cleaned surfaces that may actually
be corrosive. Kerosene films may be
removed with safety solvent, water
emulsion cleaners, or detergent
mixtures
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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Cleaning Compound for Oxygen Systems
o Clean accessible components of the ✓ Fluids must not be put into tanks or
oxygen system, such as crew masks regulators.
and lines. ✓ Instructions of the manufacturer of the
oxygen equipment and cleaning
compounds must always be followed.
EMULSION o Used in general aircraft cleaning ✓ When used in accordance with
CLEANERS o Removal of heavy deposits, such as instructions, these solvent emulsions
carbon, grease, oil, or tar. do not affect good paint coatings or
organic finishes.
Water Emulsion Cleaner
o Cleaning compound intended for use ✓ MIL-C-22543A
on both painted and unpainted aircraft ✓ A sample application must be checked
surfaces. carefully before general uncontrolled
o For cleaning fluorescent painted use.
surfaces and is safe for use on
acrylics.

Solvent Emulsion Cleaners

o Nonphenolic- safely used on painted ✓ Nonphenolic – Persistent materials
surfaces without softening the base are to be given a second or third
paint. treatment as necessary.
o Phenolic based – more effective for ✓ Phenolic based – Wear rubber gloves
heavy-duty application, but it also and goggles for protection when
tends to soften paint coatings. It must working with phenolic base cleaners.
be used with care around rubber,
plastics, or other nonmetallic materials.
Soaps and o Available for mild cleaning use
Detergents Cleaning Compound, Aircraft Surfaces
Cleaners o General cleaning of painted and ✓ MIL-C-5410 Type I and II materials
unpainted aircraft surfaces for the ✓ safe to use on all surfaces, including
removal of light to medium soils, fabrics, leather, and transparent
operational films, oils, or greases. plastics.
Nonionic Detergent Cleaners
o For softening and removing heavy ✓ May be either water-soluble or oil
preservative coatings. soluble. The oil-soluble detergent
o Similar to the emulsion cleaners cleaner is in a 3 to 5 percent solution
with dry cleaning solvent
Mechanical ✓ must be used with care and in
Cleaning accordance with directions given if
Materials damage to finishes and surfaces is to
be avoided.
Mild Abrasive Materials
o Can be used on most metals ✓ same pad should not be used on
o Powdered pumice – used for cleaning different metals
corroded aluminum surfaces.
o Impregnated cotton wadding material -
used for removal of exhaust gas stains
and polishing corroded aluminum
surfaces. It may also be used on other
metal surfaces to produce a high
reflectance.
o Aluminum metal polish – used to
produce a high luster, long lasting

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
polish on unpainted aluminum clad
surfaces. It must not be used on
anodized surfaces, because it removes
the oxide coat.
o Three grades of aluminum wool
(coarse, medium, and fine) – used for
general cleaning of aluminum surfaces.
Impregnated nylon webbing material is
preferred over aluminum wool for the
removal of corrosion products and
stubborn paint films and for the scuffing
of existing paint finishes prior to
touchup.
o Lacquer rubbing compound material –
used to remove engine exhaust
residues and minor oxidation. Avoid
heavy rubbing over rivet heads or
edges where protective coatings may
be worn thin.
o Abrasive Papers – used on aircraft
surfaces but must not contain sharp or
needlelike abrasives that can imbed
themselves in the base metal being
cleaned or in the protective coating
being maintained.
Chemical o Used with great care in cleaning ✓ The danger of entrapping corrosive
Cleaners assembled aircraft. materials in faying surfaces and
crevices counteracts any advantages
in their speed and effectiveness.
✓ All residues must be removed.
Phosphoric-citric Acid
o Cleaning aluminum surfaces ✓ Wear rubber gloves and goggles to
o Phosphoric-citric acid mixture (Type I) avoid skin contact.
is ready to use while Type II is a ✓ Any acid burns may be neutralized by
concentrate that must be diluted with copious water washing, followed by
mineral spirits and water. treatment with a diluted solution of
baking soda (sodium bicarbonate).
Baking Soda
o used to neutralize acid deposits in lead-
acid battery compartments and to treat
acid burns from chemical cleaners and
inhibitors.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Exterior Cleaning
There are three methods of cleaning the aircraft exterior: wet wash, dry wash, and
polishing. Polishing can be further broken down into hand polishing and mechanical
polishing. The type and extent of soiling and the final desired appearance determine
the cleaning method to be used.
Exterior Cleaning Method

High-pressure running water is used as a rinse. Either

alkaline or emulsion cleaners can be used in the wet
wash method
Wet wash removes oil,
grease, carbon deposits, and
most soils, except for
corrosion and oxide films.
The cleaning compounds
used are generally applied by
spray or mop.

Fig. 41 Exterior wet wash

This method is not suitable for removing heavy

deposits of carbon, grease, or oil, especially in the
engine exhaust areas. Dry wash materials are
applied with spray, mops, or cloths and removed by
dry mopping or wiping with clean, dry cloths.
Dry wash is used to remove
airport film, dust, and small
accumulations of dirt and soil
when the use of liquids is
neither desirable nor
practical.

Fig. 42 Aircraft dry wash

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control

Polishing materials are available in various forms and

degrees of abrasiveness. It is important that the
aircraft manufacturer’s instructions be used in specific
Polishing restores the luster applications.
to painted and unpainted
surfaces of the aircraft and is
usually performed after the
surfaces have been cleaned.
Polishing is also used to
remove oxidation and
corrosion.

Fig. 43 Polishing

Interior Cleaning
Keeping the interior of the aircraft clean is just as important as maintaining a clean
exterior surface. Corrosion can establish itself on the inside structure to a greater
degree, because it is difficult to reach some areas for cleaning. Nuts, bolts, bits of wire,
or other metal objects carelessly dropped and neglected, combined with moisture and
dissimilar metal contact, can cause electrolytic corrosion.
When performing structural work inside
the aircraft, clean up all metal particles
and other debris as soon as possible. To
make cleaning easier and prevent the
metal particles and debris from getting
into inaccessible areas, use a drop cloth
in the work area to catch this debris. A
vacuum cleaner can be used to pick up
dust and dirt from the interior of the flight
Fig. 44. Cabin Cleaning
deck and cabin.
Aircraft interior present certain problems during cleaning operations due to the fact that
aircraft cabin compartments are relatively small enclosures. The possibility of restricted
ventilation and quick buildup of flammable vapor/air mixtures can occur when there is
any indiscriminate use of flammable cleaning agents or solvents. Additionally, there
may also exist the possibility of an ignition source from concurrent maintenance work in
the form of an electrical fault, friction or static spark, an open flame device, etc.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
Powerplant Cleaning
Cleaning the powerplant is an
important job and must be
done thoroughly. Grease and
dirt accumulations on an air-
cooled engine provide an
effective insulation against
the cooling effect of air
flowing over it. Such an
accumulation can also cover
up cracks or other defects.
When cleaning an engine,
Fig. 45. Powerplant Cleaning
open or remove the cowling as
much as possible. Beginning with the top, wash down the engine and accessories with
a fine spray of kerosene or solvent. A bristle brush may be used to help clean some of
the surfaces. Fresh water, soap, and approved cleaning solvents may be used for
cleaning propeller and rotor blades. Except in the process of etching, caustic material
must not be used on a propeller. Scrapers, power buffers, steel brushes, or any tool or
substances that mar or scratch the surface must not be used on propeller blades,
except as recommended for etching and repair.
Water spray, rain, or other airborne abrasive material strikes a whirling propeller blade
with such force that small pits are formed in the blade’s leading edge. If preventive
measures are not taken, corrosion causes these pits to rapidly grow larger. The pits
may become so large that it is necessary to file the blade’s leading edge until it is
smooth.
Steel propeller blades have more resistance to abrasion and corrosion than aluminum
alloy blades. Steel blades, if rubbed down with oil after each flight, retain a smooth
surface for a long time.
Examine the propellers regularly, because cracks in steel or aluminum alloy blades
can become filled with oil that tends to oxidize. This can readily be seen when the blade
is inspected. Keeping the surface wiped with oil serves as a safety feature by helping
to make cracks more obvious.
Propeller hubs must be inspected regularly for cracks and other defects. Unless the
hubs are kept clean, defects may not be found. Clean steel hubs with soap and fresh
water or with an approved cleaning solvent. These cleaning solvents may be applied
by cloths or brushes. Avoid tools and abrasives that scratch or otherwise damage the
plating.
In special cases where a high polish is desired, the use of a good grade of metal polish
is recommended. Upon completion of the polishing, all traces of polish must be
removed immediately, the blades cleaned, and then coated with clean engine oil. All
cleaning substances must be removed immediately after completion of the cleaning of
any propeller part. Soap in any form can be removed by rinsing repeatedly with fresh
water. After rinsing, all surfaces must be dried and coated with clean engine oil. After

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
cleaning the powerplant, all control arms, bell cranks, and moving parts must be
lubricated according to instructions in the applicable maintenance manual.

LAB MODULE ACTIVITY 2.2

Search for innovation in method/materials/equipment used for Exterior, Interior and
Powerplant Cleaning Procedure. Fill the table formatted below and write a review from
all existing reviews of the three innovations and rate each from 1 to 5 stars (⭐ ⭐ ⭐
⭐ ⭐- use star icons for the rating)

PRODUCT NAME PRODUCT RATING

PRODUCT TYPE ABOUT THE PRODUCT

method/materials/equipment [Insert Image Here]

o Purpose in Aircraft Cleaning
e.g. Solvent – Methyl Ethyl Ketone o What of aircraft it is used?
(MEK) o How it is used?
o Advantages and
Disadvantages

References:

As an institution of higher learning, students are expected to display highest degree of honesty and professionalism in their
class work, requirements, and activities; thus, in no case that cheating—or any form of it, may it be plagiarism, copying
other students' works, and fabrication of materials—shall be tolerated. The Philippine State College of Aeronautics
assumes as a simple and minimal preferred of habits in academic matters that students be truthful and that they publish for
deposit solely the merchandise of their personal efforts.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
Laboratory Module 02: Corrosion Control
ASSESSMENT
➢ Laboratory Module Activity Rubric – for each activity.
Criteria Exceptional Satisfactory Unsatisfactory Poor
4 3 2 1
Partially
Completion Fully completed Barely Completed
completed
Did not
Accuracy Few errors Some errors Many Errors complete
Followed Followed all Followed some Did not followed
Instructions instructions instructions instructions
(Total Points /12) x 100 = Modular Activity Grade

➢ Formative Assessment – Individual Laboratory Report

Laboratory Video – Observations

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