Introduction to Corrosion

Overview
• Corrosion is the inevitable result when metals are exposed to water and air. Since
all aircraft contain some metal, they require constant inspection and cleaning to
minimize the destructive effects of corrosion.
• Dirt and grease are visually unappealing, and can hide corrosion and structural
damage. Furthermore, dirt can trap moisture and cor­rosive materials next to
aircraft structures, hastening the formation of corrosion.
• Therefore, you must be aware of proper cleaning procedures that remove built up
contamination without damaging the materials used in structural components.
• In addition, you must learn appropriate methods of corrosion control to minimize
corrosion's effects once it has become established.
 • It is a natural occurrence that attacks metal by chemical
Corrosion or electrochemical action and converts it back to a
metallic compound (oxide, hydroxide, or sulfide)
• It weakens primary structural members, which must then
be replaced or reinforced in order to sustain flight loads.
Such replacements or reinforcements are costly, time-
consuming, and result in unscheduled delays.
• It is simply a process wherein metals return to a natural
state.
• The Appearance of Corrosion varies with various metal
Aluminum and Magnesium – grey or white
Copper – Green
Steel – Red or orange
2 General Classifications of Corrosion
• DIRECT CHEMICAL CORROSION
- Chemical Corrosion resulting 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.
2 General Classifications of Corrosions
• ELECTROCHEMICAL CORROSION
if electrons equals to protons – electrically balanced
more or fewer electrons that protons – an ion
more electrons than protons – negative ion
more protons than electrons – positive ion
an Ion is unstable, always seeking to lose or gains electron, so it can change
back into a balanced, or neutral atom.
Electrochemical Series
• Metals are arranged to show the relative ease with which they ionize in what is called the
electro­chemical series.
• The earlier a metal appears in the series, the more easily it gives up electrons, 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.
• 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.
Electrochemical
Series
4 requirements for the formation of
corrosion
• 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.
Corrosive Agents
• Salt - Salts are the result of a metallic element combining with a nonmetal. The resulting
compound is almost always a good elec­trolyte, and can promote corrosive attack.
-Magnesium is particularly vulnerable to corrosive attack from an electrolyte formed by salt
solutions.
- It is very important to remember that many com­pounds other than sodium chloride fall into
the category of salts
• Water - Pure water reacts with metals to form corrosion or oxidation, but water holding a
concentration of salts or other contaminants causes much more rapid cor­rosion.
- Seaplanes are in a continual battle with the elements, and every precaution must be taken to
stay ahead of corrosion formation
Corrosive Agents
• Acids and Alkalis - Almost all acids and alkalis form effective elec­trolytes as they react with
metals to form metallic salts, but some electrolytes are more active than oth­ers.
- the sulfuric acid found in aircraft batteries is especially active in corroding alu­
minum.
- Ferrous metals are subject to damage from both acids and alkalis, but aluminum is
more vulnerable to strong alkaline solutions than it is to acids. For example, an aluminum structure
can be severely corroded if it is allowed to remain in contact with a concrete floor.
- The most destructive are sulfuric acid ( battery acid), halogen acids, nitrous oxide
compounds, and organic acids found in the wastes of humans and animals.
• Atmosphere – Major atmospheric corrosive agents are oxygen and airborne moisture.
- May also contain other corrosive gases and contaminants, particularly industrial and
marine salt spray.
Corrosive Agents
• Micro-organisms
1. Bacteria – May be either aerobic or anaerobic
Aerobic Bacteria – require oxygen to live
- Accelerate corrosion by oxidizing sulfur to produce sulfuric acid.
- Promote corrosion by depleting the oxygen supply or by releasing metabolic
products.
Anaerobic Bacteria – can survive only when free oxygen is not present
- Metabolism of these bacteria requires them to obtain part of their sustenance by
oxidizing inorganic compounds, such as iron, sulfur, hydrogen, and carbon monoxide.
2. Fungi – growths of microorganisms that feed on organic materials. Low humidity slows their
growth and may prevent corrosion damage.
3. Microbial Growth – must be removed completely by hand with a firm non-metallic bristle
brush and water.