EASA B1.1 : MODULE 6.

Corrosion Detection

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• Inspection equipment is often needed for certain
parts of an aircraft.
• Corrosion can be detected by careful visual
inspection of the airplane structure.
• The complex structure of modern aircraft makes the
use of magnifying glasses, mirrors, borescopes, fiber
optics and other optical inspection tools.

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DETECTION METHODS

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• Stress corrosion cracks are some times difficult, if not
impossible, to detect by visual inspection alone.
• Any fault that is open to the surface may be found
through a dye penetrant inspection.
• Dye penetrant cannot get in a crack that is filled with
oil or grease.

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• Porous or rough surfaces are almost impossible to
clean of all penetrant, so materials with rough
surfaces do not lend themselves this type of
inspection.

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• Another means of corrosion detection is through the
use of ultrasonic equipment.
• There are two types of ultrasonic indications used for
corrosion detection.
ULTRASONIC DETECTION (Pulse-echo)

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• Pulse-echo method, a pulse of ultrasonic energy is
directed into the structure. This energy travels
through the material to its opposite side and then
bounces back.
• The return pulse is received, it is displayed on a
screen as a spike.

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• Resonance method operates on the principle that for
any given thickness of material, there is a specific
frequency of ultrasonic energy that resonates, or
produces the greatest amount of return.

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• If metal has been eaten away by corrosion, its
resonant frequency is different from that of sound
metal.
• Ultrasonic inspection, radiological inspection such as
x-ray is used to determine if there is any corrosion on
the inside of a structure.
• X-ray inspection requires extensive training and
experience for proper interpretation of the results.

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• 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.

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 Corrosion prone areas
• Almost all parts of an airplane are subject of damage,
but certain areas are more prone than others.
Engine exhaust area
Exhaust areas must be carefully inspected and all exhaust
residue removed before corrosion has a chance to start.
Cracks in the exhaust track are prime areas for corrosion.

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Corrosion prone area (Engine exhaust areas)
Turbine engines generate power by converting chemical energy from a
hydrocarbon fuel into heat energy.

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 Battery compartments
• Airplanes having lead-acid batteries must have their
boxes protected by a material that resists corrosion
from sulfuric acid fumes.
• Airplanes with nickel-cadmium batteries must have
their battery areas protected with an alkaline-
resistant finish.
• These finishes can have a bitumastic (tar) base, a
rubber base, or can be polyurethane finishes.

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Aircraft battery compartment Bitumastic (Tar)

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• During an inspection, the areas around a battery
must be carefully checked, especially under the
battery, and all traces of corrosion must be removed
and the area refinished.

Battery corroded

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The strong acid or alkaline fumes around a battery box can
cause corrosion.

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• The battery has a sump vent jar containing an
absorbent pad moist with neutralizing agent.

• Lead-acid batteries require Bicarbonate of soda and

Boric acid is used for nickel-cadmium battery.

• These sump vent jars should be checked to see that

the pads are moist and that there is no leakage.

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• If battery electrolyte is spilled during servicing, it
must be cleaned up immediately and the area
neutralized.

• To verify an area is completely neutralized it can blot

the water on the surface with a piece of litmus paper.

• If the area is acidic, the paper turns pink, and if it is

alkaline, it turns blue.

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 Lavatories and Food Service Areas
• Organic materials such as food and human waste are
highly corrosive to aluminum surfaces.
• Food service areas can be troublesome if there is a
possibility of food debris getting into cracks under or
behind the galley where it cannot be removed.
• This material in itself may not be corrosive, it can
hold water which can cause the structure to corrode.

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Aircraft lavatories Aircraft Galley

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• Lavatory area is an especially important to check for
corrosion. Human wastes are usually acidic, and
rapidly promote corrosion if allowed to remain on
the skin of the airplane or to get into cracks and
seams in the structure.

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• Lavatories area around and behind the discharge of
relief tubes must be inspected carefully for
indications of corrosion.
• If corrosion is present, it should be removed and the
area painted with an acid-proof paint.

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 Wheel Wells and Landing Gear

• No one area of an airplane is subjected to as much

hard service as the wheel well area.
• On takeoff and landing, debris from the runway
surface is thrown up into this area.
• Abrasion can remove protective lubricants and
coating, and water and mud can freeze and cause
damage.

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 Aircraft take off

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• When inspecting for corrosion in and around wheel
wells it is important to remember that corrosion can
take place in any one of several components
including the electrical components.
• Wheel wells are corrosion-prone areas because
abrasion from water and dirt removes the protective
finish, dirt and grease can trap and hold moisture
against the aluminum.

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• Bolt heads and nuts on magnesium wheels are
susceptible to galvanic corrosion, and concentration
cell corrosion can form under the marking tape or
ferrules on aluminum tubing.

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• Many complicated shapes, assemblies, and fittings
found in the wheel well and landing gear areas,
complete coverage of the area with paint film is
difficult to attain.
• Furthermore, due to heat generated by braking
action, preservatives cannot be used on some main
landing gear wheels.

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• During inspection of this area, pay particular
attention to the following trouble spots:
1. Magnesium wheels, especially around bolt
heads and lugs, particularly for the presence water or its
effects.

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• Exposed rigid tubing, especially at B-nuts and ferrules, under
clamps and tubing identification tapes.

Rigid Tubing Tubing Identification Tapes

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• Exposed position indicator switches and other
electrical equipment.

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• Crevices between stiffeners, ribs, and lower skin
surfaces, which are typical water and debris traps.

Aircraft components

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• Manufacturer’s Maintenance Manuals give detailed
information on corrosion inspections and areas that are prone
to corrosion.

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 External Skin Areas
• One of the first places corrosion appears on the
surface of an aircraft is along seams and lap joints.
• There is also a danger of water or cleaning solvents
becoming entrapped in the lap joints and providing
an effective electrolyte.

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• Corrosion may start in a spot welded seam if the spot
welding process has left an enlarge grain structure in
the metal.

• To check for bulging along spot welds hold a

straightedge along the row of spots, and if there is a
corrosion in the seam, the surface bulges between
the spots and show up as wavy skin.

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 A spot welded seam

Bulging along spot weld

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Lap joints corrosion

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 Engine Inlet Areas
• One of the most vital parts of an aircraft is the area
directly in front of the engine where air is taken in.
• Abrasion by high-velocity air and by contaminants
carried in the air, tends to remove any protective
coating.
• Therefore, abrasion strips along the leading edge of
intake ducts help to protect these areas.

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Abrasion strip

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Engine Inlet Areas

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 Fuel Tanks
• Fuel tanks are highly susceptible to corrosion
formation, especially in jet aircraft.
• Organic growth is the primary cause of corrosion in
fuel tanks that hold turbine fuel.
• If ignored, this organic growth can grow into the
water-holding scum which attaches to the aluminum
alloy skin.

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- Scum ( A layer of dirt or froth on the surface of a liquid.)
- froth impure matter that rises to the surface of liquid.

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• Corrosion under the sealant is extremely difficult to
detect and must usually be found with x-ray or
ultrasonic inspection from the outside of the wing.

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• Microbial growth in fuel tanks and fuel systems can
result in rapid and severe corrosion.
Example:
Problems occur in aircraft wing tanks due to growth
of moulds and also yeasts and bacteria which produce
organic acids and also stimulate corrosion by creating
oxygen gradients which enhance electrochemical corrosion
cells.

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 Piano Hinges
• Piano hinges on control surfaces and access doors
are ideal locations for dissimilar metal corrosion to
develop.
• The reason for this is because the hinge body is
usually made of aluminum alloy, while the pin is
made of carbon steel.
• It is almost impossible to keep hinge crevices clean,
dirt and dust accumulate and hold moisture between
the pin and hinge body.
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Aircraft piano hinges

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Fuel access door Aircraft piano hinges

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• If corrosion within a piano hinge goes undetected the
pin may rust or freeze in the hinge, or break off and
become impossible to remove.
• To prevent piano hinges from corrosion it should be
kept as clean, dry and lubricated with a spray of
water-displacing lubricants.
• Water-displacing lubricants are manufactured to
meet MIL-C-16713 specifications.

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Water-displacing lubricants

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• An airplane that is difficult to inspect is an area
where corrosion has an opportunity to grow.
eg. Some airplanes have areas in the wing or empennage
where the moveable surfaces recess back into the fixed
structure.
Hinges are buried back in these cavities and are difficult to
lubricate.
Special attention must be paid when inspecting these areas to
remove every trace of corrosion and provide drains for any
water that might collect.

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Control Surface Recesses Empennage

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Bilge Areas –the area on the outer surface of an aircraft where the
bottom curves to meet the vertical sides
• The bottom of the fuselage below the floor is an area
where water and all forms of liquid and solid debris
can accumulate and cause corrosion.

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• Airplanes having areas prone to accumulate water
are typically provided with drain holes.

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• On every inspection, carefully inspect any area where
water might accumulate and make sure all drain
holes are clear.

• Air-powered vacuum cleaners can be used to remove

dirt or water collected in these areas.

• A water-displacing liquid spray that forms a thin film

on the surface of the metal can be used to prevent
further contact with moisture.
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 Engine Mount Structure

• When a reciprocating aircraft engine is started, the

heavy current from the starter must return to the
battery through the engine mount.

• The current flows through joints in the mount and

creates the potential difference required for
corrosion to form in these areas.

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Reciprocating Aircraft Engine

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• To protect welded steel tube mounts from internal
corrosion the tubing should be periodically filled with
hot linseed oil or other type of tubing oil.
• The oil is then drained and the drain hole plugged
with a drive screw or self-tapping metal screw.

Hot Linseed Oil

Self-Tapping Metal Screw
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 Control Cables

• Cables used in an aircraft control system are made of

either carbon steel or corrosion-resistant steel.
• If carbon steel cable is left unprotected and water is
allowed to get between the cable strands, the cable
will corrode.
• The corrosion that forms on inside of the cable is
difficult to detect.

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• Cable showing any indication of corrosion should be
replaced.
• To prevent corrosion, spray the cable with a water-
displacing type of lubricant.
• Cables in seaplane or those exposed to agricultural
chemicals, coat them with a waxy grease such as Par-
Al-Ketone.

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Aircraft Cable 7x19 ( 7strands x 19 wires )

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Aircraft Control Cables- This is the Push Pull tube for the elevators. This can move back
and forth and side to side using the control stick. Back and forth movements will move the
elevators on the tail of the airplane. Cables will attach to the welded on tab that stands
straight up. When moving the control stick side to side this will control the ailerons on the
wings.

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 Welded Areas
• Aluminum torch welding requires the use of a flux to
exclude oxygen from the weld.
• The flux may contain lithium chloride, potassium
chloride, potassium bisulphide, or potassium
fluoride.
• All of these compounds are extremely corrosive to
aluminum and all traces of flux must be removed
after welding is completed.

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• Welding flux is soluble in water and can be removed
with hot water and a nonmetallic bristle brush.

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