Ethiopian Aviation University

School of Aerospace Engineering

Aircraft Materials and Hardware

(AMGC 1371)
Aircraft Materials- Corrosion

Prepared by: Mesfin Gizaw (PhD)

E-mail: mesfingizaw@gmial.com

2024
 5. Aircraft Materials- Corrosion

 Introduction

 Type of Corrosion

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 INTRODUCTION TO CORROSION
• Corrosion is a natural occurrence that attacks metal by chemical (oxidation)
or electrochemical action (galvanic) and converts it back to a non-metallic
compound.
• Corrosion is the tendency of metals to revert to the thermodynamically
more stable, oxidized, state.
• resistance of aircraft materials to corrosion drastically change with only a
small environmental change Simplified corrosion cell showing conditions that
must exist for electrochemical corrosion

• Four conditions must exist before

electrochemical corrosion can occur
1) A metal subject to corrosion (Anode);
2) A dissimilar conductive material (Cathode),
which has less tendency to corrode;
3) Presence of a continuous, conductive liquid
path (Electrolyte); and
4) Electrical contact between the anode and
the cathode, usually in the form of metal-to-
metal contact such as rivets, bolts, and
corrosion
Elimination of corrosion by application of an organic film to metal surface. 3
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 INTRODUCTION TO CORROSION
Pure metals are not suitable for aircraft construction and are used only in combination
with other metals-Alloys
• alloys are made up entirely of small crystalline regions, called GRAINS.
• Corrosion can occur on surfaces of those regions which are less resistant and
also at boundaries bet ween regions, resulting in the formation of pits and
intergranular corrosion.

• Metals have a wide range of corrosion • Corrosion is quickened by high

resistance.
• The most active metals, (those
which lose electrons easily), such as
magnesium and aluminum, corrode
easily
• The most noble metals (those which
do not lose electrons easily), such as
gold and silver, do not corrode
easily
temperature environments that
accelerate chemical reactions and
increase the concentration of water
vapor in the air
• Electrolytes (electrically-
conducting solutions) Salt
spray, rain , dirt , acidic gases,
and engine exhaust gases can d
dissolve on wet surfaces,

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 INTRODUCTION TO CORROSION
An oxygen concentration cell corrosion occurs when-
• electrolyte on a metal surface is partially confined, (such as between surfaces
that have been joined together (faying surfaces) or in a deep crevice) the metal
around this area corrodes more rapidly.

• Corrosion increases since reduced oxygen content of the confined electrolyte

causes the adjacent metal to become anodic to other metal surfaces on the
same part that are immersed in electrolyte or exposed to air.

Slime, molds, fungi, and other living

Manufacturing processes such as
organisms (some microscopic) can
machining, forming, welding, or heat
grow on damp surfaces. Once they
treatment can leave residual stress in
are established, the area usually
aircraft parts and can cause cracking in
remains damp, increasing the
a corrosive environment.
possibility of corrosion.

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 Chemical Corrosion (Oxidation)
• Oxidation-the direct combination of a metal with the oxygen of the atmosphere.
• The phenomenon is essentially a ‘dry’ one, although water vapour, in the air, does
play a part in the oxidation of some metals
• With the exception of gold and platinum, all metals, in contact with air, form a very
thin, visible oxide film.

• Chemical corrosion caused by-

• direct exposure, of the metal surface, to caustic
liquids or gaseous agents such as:
1. Spilled battery acids or battery fumes-less
of a problem now that Nickel Cadmium
batteries are in common use

2. Flux deposits from inadequately cleaned

joints-Flux residues are hygroscopic
(readily absorb moisture).

3. Entrapped caustic cleaning compounds-

Caustic cleaning solutions should be kept
capped when not in use
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 COMMON CORROSION AGENTS
Substances that cause corrosion are called corrosive agents.
• acids, alkalies, and salts
• atmosphere and water, the t wo most common media for these substances, may
also act as corrosive agents.
• Any acid will severely corrode most of the alloys used in airframes.

• The most destructive are

• sulfuric acid (battery acid), halogen
acids (hydrochloric, hydrofluoric,
and hydrobromic), nitrous oxide
compounds, and organic acids found
in the wastes of humans and animals.
Alkalies, as a group, are not as corrosive as
acids, however, aluminum and magnesium
alloys are exceedingly prone to corrosive
attack by many alkaline solutions unless
the solutions contain a corrosion inhibitor.
• washing soda, potash (wood ashes), and
lime (cement dust).-corrosive to Al
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MICRO ORGANISMS
• Aerobic bacteria require oxygen to
live. They accelerate corrosion by
oxidizing sulfur to produce sulfuric
acid
• Anaerobic bacteria-(no free oxygen
area)
• oxidize inorganic compounds,
such as iron, sulfur, hydrogen,
and carbon monoxide
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 COMMON CORROSION AGENTS
Damage resulting from microbial growth can occur when any of three basic
mechanisms, or a combination of these, are brought into play.
1. fungi have a tendency to hold moisture which contributes to other forms of
corrosion.
2. fungi are living organisms, they need food to survive. This food is obtained
from the material on which the fungi are growing.
3. these micro organisms secrete corrosive fluids that attack many materials,
including some that are not fungi nutrient.

Microbial growth should be removed by-

• Hand with a firm non-metallic
bristle brush and water
• with steam at 100 psi. Protective
clothing must be used when using
steam for removing microbial
growth.

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 COMMON CORROSION AGENTS

• Factors affect the type, speed, cause, and seriousness of metal corrosion. Some of these factors
that influence metal corrosion and the rate of corrosion are:-

1. Type of Metal
2. Heat-treatment and grain direction
3. Presence of a dissimilar, less corrodible metal
4. Anodic and cathodic surface areas (in galvanic corrosion)
5. Temperature
6. Presence of electrolytes (hard water, salt water, battery fluids, etc.)
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

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 CORROSION TYPES
A. GENERAL SURFACE CORROSION
All corrosive attacks begin on the surface of the metal making the classification of
corrosion by physical appearance a convenient means of identification.
• Uniform Etch or Uniform Attack Corrosion
• most common form of corrosion and results from a direct chemical attack on a
metal surface and involves only the metal surface
• more or less equal in dispersion
• On a polished -first seen as a general du l ling of the surface-becomes rough
and possibly frosted in appearance.

• discoloration or general dulling of metal created

by exposure to elevated temperatures is not to
be considered general surface corrosion

• ‘Pure’ aluminum, stainless steel and copper have

more resistance to surface corrosion than
aluminum alloy, magnesium alloy and non- Surface corrosion.
stainless steels.
• Oxidation is an example of surface corrosion
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 CORROSION TYPES
B. PITTING CORROSION
All corrosive attacks begin on the surface of the metal making the classification of
corrosion by physical appearance a convenient means of identification.
• most destructive and intense forms of corrosion
• metals that form protective oxide films, such as aluminum and magnesium
alloys
• white or gray powdery deposit, similar to dust, which blotches the surface.
• when the deposit is cleaned away, tiny holes or pits can be seen in the surface

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 CORROSION TYPES
B. PITTING CORROSION

• The oxide film that forms on metals, generally tends to protect them
from further corrosive attack. The oxidation rate normally falls
sharply as the film thickness increases so that, at some time, there is
virtually no further increase in film thickness-Chemical Corrosion
(Oxidation)

• Aluminum and magnesium

alloys, chromium plated and
stainless steels (including nitride
surfaces), are all particularly
susceptible to this form of
corrosion.
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 CORROSION TYPES
B. PITTING CORROSION

• Types of pitting corrosion

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 CORROSION TYPES
C. Dissimilar Metal CORROSION

• Extensive pitting damage may result from contact between dissimilar metal parts in the
presence of a conductor.
• a galvanic action occurs at the points or areas of contact where the insulation between the
surfaces has broken down or been omitted.
• contamination of a metal’s surface by mechanical means can also induce dissimilar metal
corrosion.

• 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,
causing corrosion and ruining the adjoining surface.

Dissimilar metal corrosion

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 CORROSION TYPES
D. CONCENTRATION CELL CORROSION (Crevice CORROSION)

• Crevices are liable to preferential attack, usually by a differential aeration form

of corrosion, intensified by the high ratio of cathode to anode area involved.
The attack is more severe where crevices collect dust and moisture.

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 CORROSION TYPES
D. CONCENTRATION CELL CORROSION (Crevice CORROSION)
• Typical locations of oxygen concentration cells are under gaskets, wood, rubber,
and other materials in contact with the metal surface. Corrosion will occur at the
area of low oxygen concentration (anode). Alloys such as stainless steel are
particularly susceptible to this type of crevice corrosion.-Chemical Corrosion
(Oxidation)

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 CORROSION TYPES
E. ACTIVE-PASSIVE CELLS
• Metals which depend on a tightly adhering passive film, usually an oxide, for
corrosion protection are prone to rapid corrosive
• often referred to as a type of concentration cell corrosion.
• two forms of corrosion working in conjunction. The corrosive action usually
starts as an oxygen concentration cell.
• As an example, salt deposits on the metal surface in the presence of water
containing oxygen can create the oxygen cell. The passive film will be broken
beneath the salt crystals.
• Once the passive film is broken, the active metal beneath the film will be
exposed to corrosive attack.

Rapid pitting of the active metal

• the reaction is augmented by the affected
area, since the proportion of the exposed
base metal is small compared to the
surrounding nonreactive metal.
• focal point of the reaction, often resulting
in deep pits in a short time and a greater
rate of corrosion.
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 CORROSION TYPES
F. FILIFORM CORROSION
• Special form of oxygen concentration cell which occurs on metal sur faces
having an organic coating system. It is recognized by its characteristic worm-
like trace of corrosion products beneath the paint film.
• occurs beneath thin, protective coatings, on aluminum and steel alloys, with the paint or
coating often bulging or blistering. On aircraft structures, the attack often starts at
fasteners and extends as thread-like lines of corrosion under the paint. It may not be
readily visible until it has become quite severe. The damage tends to be very shallow and
is not, usually, structurally dangerous.

Filiform corrosion.

Poly urethane finishes are especially susceptible to filiform corrosion. Filiform occurs when the
relative humidity of the air is between 78-90% and the surface is slightly acidic
• usually attacks steel and aluminum surfaces
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 CORROSION TYPES
F. FILIFORM CORROSION
• the traces never cross on steel, but they will on aluminum which makes the damage
deeper and more severe for aluminum. Not treated-can lead to intergranular
corrosion,
• removed using glass bead blasting material with abrasive blasting equipment or
sanding
• thread-like bulges appearing under paint surfaces, usually originating at a fastener,
are often referred to as ‘worm-casts’.

Filiform can be prevented by

• storing aircraft in an environment
with a relative humidity below 70
percent,
• using coating systems having a
low rate of diffusion for oxygen
and water vapors, and
• washing the aircraft to remove
acidic contaminants from the Filiform corrosion.
surface

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 CORROSION TYPES
G. INTERGRANULAR CORROSION
an attack on the grain boundaries of a metal
• The grain boundary and the grain center can react with each other as anode and
cathode when in contact with an electrolyte
• Rapid selective corrosion of the grain boundaries can occur. High strength
aluminum alloys such as 2014 and 7075 are more susceptible to intergranular
corrosion if they have been improperly heat treated and then exposed to a corrosive
environment.

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 CORROSION TYPES
H. EXFOLIATION CORROSION
• An advanced form of intergranular corrosion and
• shows itself by lifting up the surface grains of a metal by the force of expanding
corrosion products occurring at the grain boundaries just below the surface.
• visible evidence of intergranular corrosion and is most often seen on extruded
sections where grain thickness are usually less than in rolled forms

• often attacks 7000 series

aluminum alloys (those with
an appreciable amount of
Zinc). When the corrosion
occurs well below the surface,
extensive damage can occur
before the surface
deformation is apparent.
• Spars, stringers and other
high-strength parts, which are
extruded or hot rolled-poor
heat treatment

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 CORROSION TYPES
I. Stress CORROSION
• is a cracking process, caused by the combined action of a sustained tensile stress
and a corrosive environment
• Only certain combinations of alloys and environments result in stress corrosion
cracking, although this type of failure may occur at stresses well below the yield
strength of the alloys

Stress corrosion cracking.

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 CORROSION TYPES
I. Stress CORROSION
• high-strength structural alloys, used in aircraft.-in marine environments
• In aircraft alloys, the principal stresses, causing this stress corrosion cracking, are not the
applied service loads, but the stresses developed within the metal during manufacture and
during assembly.
• For example, internal stresses can arise from quenching after heat treatment, from ‘force fits’,
from badly mating parts, or from welding procedures. Service stresses are only significant
when they act in the same direction as internal or assembly stresses.
Stress corrosion cracking has three distinct
phases
• initial ‘Incubation’ period, (when a stress corrosion
crack starts from pitting or film breakdown)

• ‘Slow Growth’ of the stress concentrations and

• culminates in a short, ‘Rapid Crack-Growth’ rate

• e.g. landing gear components-cracks may
originate from

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 CORROSION TYPES

J. GALVANIC CORROSION
two dissimilar metals make contact in the
presence of an electrolyte
• known as Dissimilar Metal corrosion
• recognizable by the presence of a build
up of corrosion at the joint between the
metals
• Typical problem areas are rivets or
bolts made form a different material to
that of the sheet metal to which they are
located

Galvanic corrosion

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 CORROSION TYPES
K. FATIGUE CORROSION
• involves cyclic stress and a corrosive environment
• Once the fatigue limit has been exceeded, the metal will eventually crack and fail
from metal fatigue
• part or structure undergoing cyclic stress in a corrosive environment, the stress level for
failure may be reduced many times. Thus, failure occurs at stress levels that can be
dangerously low depending on the number of cycles assigned to the life-limited part.

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 CORROSION TYPES
K. FATIGUE CORROSION

Fatigue corrosion failure occurs in two stages

• first stage the combined action of corrosion • 2nd essentially a fatigue stage in which
and cyclic stress damages the metal by failure proceeds by propagation of the
pitting and crack formations to such a crack (often from a corrosion pit or pits). It
degree that fracture by cyclic stress will is controlled primarily by stress
occur concentration effects and the physical
properties of the metal

Fracture of a metal part due to fatigue corrosion, generally occurs at a

stress level far below the fatigue limit of an un corroded part, even
though the amount of corrosion is relatively small

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 CORROSION TYPES
L. FRETTING CORROSION
• also known as wear corrosion or friction oxidation
• can occur at the interface of two highly loaded surfaces which are not supposed to move
against each other. -vibration may cause the surfaces to rub together resulting in an abrasive
wear known as fretting
• The protective film on the metallic surfaces is removed by this rubbing action.
• With continued rubbing, metal particles sheared from the surface of the metal combine with
oxygen to form metal oxide. As these oxides accumulate, they cause damage by abrasive
action and increased local stress

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 CORROSION TYPES
l. FRETTING CORROSION
• The most common example of fretting corrosion is the smoking rivet found on engine cowling
and wing skins. This is one corrosion reaction that is not driven by an electrolyte and, in fact,
moisture may inhibit the reaction. Application of a lubricant or installation of a fretting-
resistant material between the two surfaces can reduce fretting corrosion.

Fretting corrosion

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 Reading for Assignment

 Detection of Defects/Deterioration in Composite

 Factors Affecting Corrosion

 Common Metals and Corrosion Products

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