CORROSION

Contributing causes of corrosion --

Environmental
◦ Volcanic gases-corrosive gases from volcanoes are carried in the atmosphere. There is also a fall out zone
down wind of active volcanoes. This could be not desirable in some areas.

◦ Airborne abrasive – Blowing sand or coral dust has an erosive effect on the finish and may find its way into
the interfacing surfaces of moving parts or into bearings, This abrasion not only creates a wear problem, It
exposes unprotected metal to corrosion. The abrasive metal itself may also be corrosive, as would be the case
with sand from salt water beaches.
◦ Airplane that operate on relatively low altitudes are exposed to more airborne pollutants than airplane that
operate at higher altitudes.
◦ Rainfall
◦ Moderate rainfall in temperate or cold climates does not constitute an environmental problem. Heavy rain fall
or hail can damage the finish. This can start corrosion . Tropical rain cause a hot, humid atmosphere that
causes corrosion.
◦ Relative Humidity and Temperature
◦ A high relative humidity combined with high temperature results in water saturated atmosphere in the
airplane while it is on the ground. After take off, condensation occurs. This allow for the opportunity for
the start of corrosion . High humidity at lower temperature is less of the problem. The best conditions are
those with a low relative humidity.
◦ High temperature and low humidity is the best condition. This is because any moisture in the airplane is
dried out. Also an extreme cold atmosphere is also usually dry. An example of this would be an artic
climate. However ,combination of high temperatures and high humidity provide the least desirable
environment from the corrosion standpoint.

◦
MOISTURE IN THE AIR
◦ - Contains contaminants
◦ - Can be trapped in faying surfaces
◦ - Can be pulled in poor bond lines

OPERATING ENVIRONMENT
- Marine atmosphere
- Contaminated (Polluted Atmosphere)
◦ - Pollutant
◦ - Volcanic Gases
◦ - Airborne abrasives
RAINFALL
RELATIVE HUMIDITY
TEMPERATURE
Contributing Causes of Corrosion –
Basic Design and Manufacturing Processes
◦ In the design phase, selection of metal or alloy for the particular environmental conditions,(composition,
temperature velocity etc.) is an important factor. If the metal has to be protected, provision for applying
metallic or non metallic coatings are applying anodic or cathodic protection must be considered .
Geometric configurations that trap dust, moisture and water must be avoided. Good drainage must be
provided. Crevices where deposits can form on the metal surfaces must be filled with sealant. Avoid
stresses(magnitude and type) and environmental conditions that lead to stress corrosion cracking ,
corrosion fatigue, or fretting corrosion . Thicker parts are more susceptible to corrosion due to their
varying composition.

◦ FINISH DETERIORATION
◦ Are exposed to adverse conditions. This can also damage the protective finish and leave corrosive
materials on the surfaces of skin, flight control surfaces and landing gears. Chipped or missing paints can
create an environment that can cause corrosion.
Categories of Operating Environment
To establish the corrosion prevention program to meet the individual requirements of an operators, It must
first be ascertained how severe the operating environment is geographically, and then establish frequencies
of inspection and prevention procedures to suit the route structure. Three categories of operating
environment have been establish as follows:

◦ - Severe- Areas I which there is marine atmosphere or industrial atmosphere containing contaminants.
Hot humid tropical areas also come within the severe category.
◦ - Moderate- Temperature regions with other than marine or industrial polluted atmospheres.
◦ - Mild- Warm zone or areas subject to extremely low temperatures. However the use of chemicals on
runways and taxi ways to prevent ice formation may transfer cold zones to the severe category.

The operating environment is defined as being equivalent to the worst area of operation on the route
structure on which the airplane is being used.Thus , an airplane starting in mild location but flying to a
severe environment. The frequency of airplane washing is very dependent upon the operating environment
an airplane is use in.
◦ ENVIRONMENTAL CONDITION WITHIN AIRPLANE
◦ Frequent cycling of airplane will creates a greater moisture buildup than is on an airplane used for long
stage lengths . This is especially true of airplanes used in hot and humid zones. This is because airplane
is being exposed to a fresh supply of water saturated air at every landing. The moisture will then
condense out in the subsequent flight. Wet insulation blankets , plugged drain holes and passages,
trapped water can create an environment that can cause corrosion
◦ ACCIDENTAL CONTAMINATION due to SPILLAGE AND CARGO
Users must avoid fluid spillage that creates and electrolytic environment for corrosion to start . Spills of
many acids or alkalines may result in significant damage unless cleaned up promptly and properly If
maintenance inspections are not frequent enough, acidic fluid spills( battery, orange juice , coffee etc.).
And lavatory fluids can have severe corrosion effects if left unchecked.

Special steps need to be done when you transport live stock or corrosive cargo . These are several factors
such as humidity release of salt from the body, waste spills and so . These will, require special corrosion
detection techniques as well.
MAINTENANCE PROBLEM AREAS

◦ Users must ensure that the protective coating or finished is applied, maintained and inspected in
accordance with the specification or code of practice. Timely scheduling of maintenance checks can
prevent a minor problems from turning into expensive repairs.
CONTRIBUTING CAUSES OF CORROSION – CORROSIVE AGENTS
◦ Substances that cause corrosion of metals are called corrosive agents
◦ ACIDS
◦ Typically, moderate strong acids will cause severe corrosion on most of the alloys used in airframes. The
acids that cause the most destruction are sulfuric acids (battery acids), halogen acids (such as, and
hydrobromic hydrochloric , hydrofluoric), nitrous oxide compounds and organic acids that are in human and
animal wastes.

◦ ALKALIES
◦ Typically alkalies are not as corrosive as acids, But aluminum and magnesium alloys are very susceptible to
corrosive attack by many alkali solutions. Very corrosive to aluminum are washing soda, potash(wood ashes)
, and lye ( cement dust). Amonia , an alkali is not corrosive because aluminum alloys are very resistant to it.
◦ SALTS
◦ Most salt solution are good electrolytes and cause corrosive attack. Some stainless steel alloy are resistant to
attack by salt solutions. But aluminum alloys. Magnesium alloys, and other steels rea very susceptible.
Exposure of airframe materials to salts or their solutions is extremely undesirable
THE ATMOSPHERE
◦ The largest corrosive agents in the atmosphere are oxygen and airborne moisture. Corrosion is often
caused by the action of oxygen in the atmosphere and the moisture on metal surface. If there is a lot of
moisture present, the rate of corrosion can increase. This is specially on ferrous alloys. The atmosphere
can also have other corrosive gasses and contaminants such as industrial and marine environments.
◦ WATER
◦ How corrosive the water is, depends on the type and amount of dissolved mineral and organic impurities
and dissolved gasses (particularly oxygen) that are present in the water. One characteristics of water
which determine how corrosive it is, is its conductivity. This its ability to act as an electrolyte and
conduct a current.
◦ The most corrosive of natural waters ( sea and fresh waters) are those that contain salt. Water on the pen
sea is very corrosive because chloride ions are present. However, waters in harbors can be more
corrosive they are contaminated by industrial waste.
◦ HYDRAULIC FLUIDS
◦ Leaking or spilling of hydraulic fluid on the titanium parts which are hot, or will later be at high
temperature(above 270b degrees fahrenheit (132 celsius) can cause hydrogen embrittlement, when the
titanium ducts are under high pressure , the effect can be an explosive failure
LAVATORY FLUIDS
◦ When lavatory cleanout valves and are not correctly closed and sealed, leaking can occur in flight while
under cabin pressure.
◦ The leaking effluent will then streak back on the fuselage exterior. This highly corrosive material has
been known toa cause severe damage to:
◦ -Window frame forging
◦ - Skin and doublers around the emergency exit hatches
◦ - Interior of the fuselage behind the aft pressure bulkhead where it maybe ingested due to negative
pressure.

◦ SNOW AND ICE REMOVAL

◦ Chemicals that are applied to runways and taxiways to remove snow and ice can be very corrosive. This
is specially noted in the landing gear and surrounding areas, to the wheel wells, and to the leading edges
cavities of the wings.
FIRE EXTINGUISHERS
◦ The chemicals that remain from when you use fire extinguishers are a possible source of corrosion . The
sooty deposits when organic material burn is also source of corrosion.

◦ OTHER SOURCES
◦ Others sources of corrosion agent includes:
◦ - The wrong use of chemicals
◦ - Spilling maintenance materials such as dis infectants, deodorants and cleaning fluids and paint strippers.
◦ - Contamination from items carried as cargo such as, sea food products, live animals and shipments of concentrated
chemicals.
CONCLUSION
If you do not immediately neutralize and remove the above materials, all te above sources can cause severe and
progressive damage. Seeping chemicals can get into faying surfaces and other crevices. The are difficult to find and
remove. This a treat to structural integrity