Instructor: Engr. Ysmael I.

Caballero
PRC No. 001016
Training Date: July 22, 2023 | 1000H – 1700H
 Aircraft corrosion is rust that appears on the
metal surfaces and components of an aircraft.
It occurs when unprotected metal comes into
contact with oxygen in the atmosphere.
Why do metals corrode?

Most metals are found in nature as ores. The manufacturing process of

converting these ores into metals involves the input of energy. During
the corrosion reaction the energy added in manufacturing is released,
and the metal is returned to its oxide state.

In the marine environment, the corrosion process generally takes place

in aqueous solutions and is therefore electrochemical in nature.
Why do metals corrode?

1. ANODE - the metal or site on the metal where oxidation occurs (loss of
electrons). The anode has a more negative potential with respect to
(wrt) the cathode and is termed less noble wrt the cathode.

2. CATHODE - the metal or site on the metal where reduction occurs (gain
of electrons). The cathode has a more positive potential wrt the anode
and is termed more noble wrt the anode.

3. ELECTROLYTE - the electrically conductive medium in which the anode

and cathode reside.

4. ELECTRICAL CONNECTION - the anode and the cathode must be

electrically connected.

5. POTENTIAL DIFFERENCE - a voltage difference must exist between the

anode and the cathode.
Why do metals corrode?
 There are two general classifications of corrosion that cover most of the
specific forms: 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. 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 Attack
 Direct chemical attack, or pure chemical corrosion, is an attack resulting
from direct exposure of a bare surface to caustic liquid or gaseous agents.
Unlike electrochemical attack where anodic and cathodic changes take place
a measurable distance apart, the changes in direct chemical attack occur
simultaneously at the same point. The most common agents causing direct
chemical attack on aircraft are: spilled battery acid or fumes from batteries;
residual flux deposits resulting from inadequately cleaned, welded, brazed,
or soldered joints; and entrapped caustic cleaning solutions.
Electrochemical Attack
 Corrosion is a natural occurrence that attacks metal by chemical or
electrochemical action, converting it back to a metallic compound. The
following four conditions must exist before electrochemical corrosion can
occur.
1. A metal subject to corrosion (anode)
2. A dissimilar conductive material (cathode) that has less tendency to corrode
3. Presence of a continuous, conductive liquid path (electrolyte)
4. Electrical contact between the anode and the cathode (usually in the form of metal to metal
contact, such as rivets, bolts, and corrosion)

 Elimination of any one of these conditions stops electrochemical corrosion.

 Surface corrosion: The most common type of aircraft corrosion, surface
corrosion occurs when metal on the surface of an aircraft oxidizes, such as
when paint wears away. Typically, you can recognize surface corrosion by the
roughening, pitting or etching of surface metal and the presence of grey-
white powdery deposits on aluminum. However, another type of surface
corrosion called filiform corrosion may resemble small worms underneath
the paint surface, eventually leading to bubbling and cracking.
 Surface corrosion:
 Dissimilar metal corrosion: Dissimilar metal corrosion appears when
dissimilar metal parts come into contact with each other in the presence of a
conductor. This type of electrochemical corrosion can cause extensive pitting
damage. It often takes place out of sight, making it particularly dangerous.
 Intergranular corrosion: This type of corrosion affects the grain boundaries
of an alloy, so it’s often related to a lack of uniformity in alloy structure.
Although intergranular corrosion often exists without surface evidence, it can
lead to the lifting and flaking of surface metal over time. Extruded
components may be particularly susceptible.
 Intergranular corrosion:
 Stress corrosion: As the name suggests, stress corrosion develops when
parts such as landing gear and engine crankshafts are put under sustained
tensile stress in corrosive environments, sometimes leading to cracking and
failure.

Specific environments have been identified that cause stress corrosion cracking of certain alloys.
 Salt solutions and sea water cause stress corrosion cracking of high-strength, heat-treated steel and
aluminum alloys.
 Methyl alcohol-hydrochloric acid solutions cause stress corrosion cracking of some titanium alloys.
 Magnesium alloys may stress corrode in moist air.
 Stress corrosion:
 Fretting corrosion: Fretting corrosion is caused by the slight relative motion
of two mating surfaces on an aircraft. Characterized by significant pitting
and fine debris, this type of aircraft corrosion is greatly accelerated when
water vapor is present.
Many 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

Pure Metals
 Most pure metals are not suitable for aircraft construction and are used only
in combination with other metals to form alloys. Most alloys are made up
entirely of small crystalline regions called grains. Corrosion can occur on
surfaces of those regions that are less resistant and also at boundaries
between regions, resulting in the formation of pits and intergranular
corrosion. Metals have a wide range of corrosion resistance. The most active
metals (those that lose electrons easily), such as magnesium and aluminum,
corrode easily. The most noble metals (those that do not lose electrons
easily), such as gold and silver, do not corrode easily.
Climate
 The environmental conditions that an aircraft is maintained and operated
under greatly affects corrosion characteristics. In a predominately marine
environment (with exposure to sea water and salt air), moisture-laden air is
considerably more detrimental to an aircraft than it would be if all operations
were conducted in a dry climate. Temperature considerations are important,
because the speed of electrochemical attack is increased in a hot, moist
climate.
Geographical Location
 The flight routes and bases of operation expose some airplanes to more
corrosive conditions than others. The operational environment of an aircraft
may be categorized as mild, moderate, or severe with respect to the
corrosion severity of the operational environment.
Foreign Material
 Among the controllable factors that affect the onset and spread of corrosive
attack is foreign material that adheres to the metal surfaces. Such foreign
material includes:
◦ 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
Micro-organisms
 Slimes, molds, fungi and other living organisms (some microscopic) can grow
on damp surfaces. Once they are established, the area tends to remain
damp, increasing the possibility of corrosion.
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. It is important that aircraft be kept clean. How often and to
what extent an aircraft must be cleaned depends on several factors,
including geographic location, model of aircraft, and type of operation.
It defines minimum requirements for preventing or
controlling corrosion problems that may jeopardize
continuing airworthiness of the aircraft. To meet these
requirements, operators must have effective corrosion
prevention and control procedures incorporated into the
maintenance program for all airplanes reaching or exceeding
the Implementation Age defined for each airplane area.