CORROSION

Corrosion-
 Metal corrosion is the deterioration of the
metal by chemical or electrochemical attack.
 This type of damage can take place internally as
well as on the surface.
 This deterioration may change the smooth
surface, weaken the interior, or damage or
loosen adjacent parts.
 Water or water vapor containing salt combines
with oxygen in the atmosphere to produce the
main source of corrosion in aircraft.
 Aircraft operating in a marine environment, or
in areas where the atmosphere contains
industrial fumes that are corrosive, are
particularly susceptible to corrosive attacks.
Appearance Of Corrosion On
Various Metal
 On the surface of aluminum alloys and
magnesium, it appears as pitting and etching,
Blistering or Flaking, and is with a gray or
white powdery deposit.
 On copper and copper alloys, the corrosion
forms a greenish film;
 on steel, a reddish corrosion byproduct
commonly referred to as rust.
 Alloy or Carbon steel, red rust & pitting.
 CRS – Black pits or a uniform reddish brown
surface.
Types of Corrosion
 There are two general classifications of
corrosion: Direct Chemical Attack and
Electrochemical Attack.
 In both types of corrosion, the metal is
converted into a metallic compound such as
an oxide, hydroxide, or sulfate.
 Aluminum may be converted into aluminum
sulphate by battery acid.
 Corrosion is a natural occurrence that
attacks metal by chemical or electrochemical
action and converts it back to a metallic
compound.
1. Direct Chemical Attack
 Direct chemical attack, or pure chemical
corrosion, is an attack resulting from a direct
exposure of a bare surface to caustic liquid or
gaseous agents.
 The changes in direct chemical attack are
occurring simultaneously at the same point.
 The most common agents causing direct
chemical attack on aircraft are:
I. Spilled battery acid or fumes from batteries;
II. Residual flux deposits resulting from
inadequately cleaned, welded, brazed, or
soldered joints; and
III. Entrapped caustic cleaning solutions.
2. Electrochemical Attack
 The electrolytic reaction that takes place in
electroplating, anodizing, or in a dry cell
battery.
 The reaction in this corrosive attack
requires a medium, usually water, which is
capable of conducting a tiny current of
electricity.
 This potential is commonly referred to as
the metal’s “nobility.”
 The less noble a metal is, the more easily it
can be corroded.
Forms of Corrosion-
1. Surface Corrosion (Uniform Etch or
Uniform Attack Corrosion)
 Appears as a general roughening, etching, or
pitting of the surface of a metal, frequently
accompanied by a powdery deposit of
corrosion products.
 Direct chemical or electrochemical attack.
 The paint or plating is lifted off the surface in
small blisters.
 Involves only the metal surface.
 Recognized by either the roughening of the
surface or the powdery deposit.
Pitting corrosion occurs on metals that form
protective oxide films, such as aluminum and
magnesium alloys

2. Dissimilar Metal Corrosion

(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.
3. Intergranular Corrosion
 Attack along the grain boundaries of an alloy and
commonly results from a lack of uniformity in the
alloy structure.
 Exist without visible surface evidence &may be
visible through Magnifying Glass.
 The attack is transgranular & it is the material
adjacent to boundary which is attacked.
 Repeated Tensile or Fluctuation stresses
encourage separation of the boundaries, so
acceleration the spread of intergranular
corrosion.
 Occurs due to improper heat treatment.
 Ultrasonic and eddy current inspection methods
are used.
4. Stress Corrosion
 Occurs as the combined effect of Tensile
Stresses (corrosion involves a constant or
cyclic stress), and a Corrosive Environment.
 Occurs along lines of cold working and may
be transgranular or intergranular in nature.
 Aluminum alloy bell cranks with pressed in
bushings, landing gear shock struts with
pipe thread type grease fittings, clevis pin
joints, shrink fits, and overstressed tubing B-
nuts are examples of parts which are
susceptible to stress corrosion cracking.
5. Fretting Corrosion (wear corrosion
or friction oxidation)
 Occurs when two mating surfaces, normally at
rest with respect to one another, are subject
to slight relative motion.
 The most common example of fretting
corrosion is the smoking rivet found on engine
cowling and wing skins.
 Bolts securing engine mountings, wing &
Empennage attachment & undercarriage
assembly should be examined for sign of
fretting corrosion.
 It is characterized by pitting of the surfaces
and the generation of considerable quantities
of finely divided debris.
 If the contact areas are small and sharp, deep
grooves resembling brinell markings or pressure
indentations may be worn in the rubbing surface.
 As a result, this type of corrosion (on bearing
surfaces) has also been called false brinelling.

6. Filiform Corrosion.
 Filiform corrosion gives the appearance of a series
of small worms under the paint surface.
 It is often seen on surfaces that have been
improperly chemically treated prior to painting.
 Filiform corrosion usually occurs under thin oil,
grease or varnish films & is likely to be found on
metal surface which have protective finish or
coating.
7. Crevice Corrosion (Concentration
cell corrosion)
 Corrosion is often found where non
conducting material such as plastic, glass-
wool or upholstery are in contact with
metal.
 A similar effect may occurs in inaccessible
corners formed in metal parts.
 The contact of metals and non conductors
should be treated like dissimilar metals &
that all enclosed region in aircraft structure
should be vented & drained as adequately
possible.
8. Exfoliation Corrosion
 Exfoliation corrosion is an advanced form
of intergranular corrosion.
 This is a lifting or flaking of the metal at the
surface due to delamination of the grain
boundaries caused by the pressure of
corrosion residual product buildup.
 Extruded components such as spars can be
subject to this type of corrosion.
9. Marine corrosion-
 The salt present in sea water will attack
many metals directly.
10. Fatigue corrosion-
 Fatigue corrosion involves cyclic stress and
a corrosive environment.
11. Microbiological contamination-
 Occurs in aircraft fuel tanks due to the
growth of micro-organisms which require
the water content of kerosene fuels for
their development.
 Fuel, Oil & Other Liquid- the dangerous of
corrosion chiefly arises from the water
content in fuel & oil.
 Integral fuel tanks should be designed to give
good water collection & drainage.
 The heating caused by friction promotes
oxidation of steel parts & the oxide is then
rubbed off to form dust frequently described
as “cocoa”.
 Intergranular corrosion in welded joint can be
reduced if the part is annealed after welding or
if the steel contain stabilizing element such as
titanium or niobium.
 Inert gas welding process which do not
require flux is used where removal of flux is
difficult.
Factors Affecting Corrosion
 Climate-
 Foreign Material-
 Soil and atmospheric dust.
 Oil, grease, and engine exhaust residues.
 Salt water and salt moisture condensation.
 Spilled battery acids and caustic cleaning
solutions.
 Welding and brazing flux residues.
Preventive Maintenance
 Corrosion preventive maintenance includes the
following specific functions:
1. Adequate cleaning
2. Thorough periodic lubrication
3. Detailed inspection for corrosion and failure of
protective systems
4. Prompt treatment of corrosion and touchup of
damaged paint areas
5. Keeping drain holes free of obstructions
6. Daily draining of fuel cell sumps
7. Daily wipe down of exposed critical areas
8. Sealing of aircraft against water during foul weather
and proper ventilation on warm, sunny days
9. Maximum use of protective covers on parked
aircraft
Corrosion Prone Areas
 Exhaust Trail Areas
 Battery Compartments and Battery Vent Openings
 Bilge Areas
 Wheel Well and Landing Gear-
During inspection of this area, pay particular attention
to the following trouble spots:
1. Magnesium wheels, especially around bolt heads,
lugs, and wheel web areas, particularly for the
presence of entrapped water or its effects
2. Exposed rigid tubing, especially at B-nuts and
ferrules, under clamps and tubing identification tapes
3. Exposed position indicator switches and other
electrical equipment
4. Crevices between stiffeners, ribs, and lower skin
surfaces, which are typical water and debris traps
 Water Entrapment Areas
 Engine Frontal Areas and Cooling Air Vents
 Wing Flap and Spoiler Recesses
 External Skin Areas-
 Piano-type hinges are prime spots for
corrosion due to the dissimilar metal
contact between the steel pin and
aluminum hinge.
Material types & corrosion products
 Iron & Steel- oxide (rust)- Red color
 Aluminum & Aluminum Alloy- corrosion evident
as general etching, pitting, or roughness of the
surfaces.
 White and generally more voluminous than the
original base metal.
 Magnesium Alloys- the easiest type of corrosion
to detect in its early stages, since magnesium
corrosion products occupy several times the
volume of the original magnesium metal destroyed.
 Beginning of attack shows as a lifting of the paint
films and white spots on the magnesium surface.
 These rapidly develop into snow-like mounds or
even “white whiskers.”
 Titanium and Titanium Alloys- difficult to
detect.
 Copper Alloys- Greenish film.
Surface corrosion
Filiform corrosion
Dissimilar metal corrosion
Intergranular corrosion