1

CORROSION
CONTENTS

1. CorrosionControl
2. DegradationofMaterial
3. Discolorationofmetal
4. TwoMajorFormsofCorrosion
5. FactorsAffectingCorrosion
6. TypesofCorrosiononAircraft
7. PreventiveMaintenance
8. Inspection
9. AircraftCleaning
10. ChemicalCleaners
11. SoapsandDetergentCleaners
12. EmulsionCleaners
13. MechanicalCleaningMaterials
14. PowerplantCleaning
15. CorrosionRemoval
16. IdentificationofMetals
17. CorrosionofFerrousMetals
18. CorrosionofAluminumandMagnesiumAlloys
19. TreatmentofTitaniumandTitaniumAlloys
20. Permanent Anti-Corrosion Treatments
21. ProtectionofDissimilarMetalContacts

Corrosion Control

Aloha Airlines Boeing 737

F-15 air crash

Qantas Jumbo 747

Corrosion Control

DegradationofMaterial

Discoloration of metal

Gray on Aluminum

White on
Magnesium

Green on
Copper

Red Rust on Iron

Corrosion Control

Types of Corrosion

Direct Chemical Attack

Electrochemical
Attack

11

Corrosion Control

Direct Chemical Attack

11

Corrosion Control

Electrochemical Attack

11

Iron Corrosion

Factors Affecting
Corrosion

i.

Soil and atmospheric dust

ii.

Oil, grease and engine exhaust residues

iii. Salt water and salt moisture condensation

iv. Spilled battery acids and caustic cleaning
solutions

29

Factors Affecting Corrosion

11

Size & Type of Metal

NOBILITY OF METAL IN SALT

WATER

Magnesium
Zinc
Cadmium
Mild Steel
Aluminum Alloyed
Lead
Brass
StainlessSteel
Monel
Silver
Gold
Platinum

MORE NOBLE

28

Atmospheric conditions

HumidEnvironment

RATE OF CORROSION

EXTREME
HIGH
LOW
MINIMAL

RELATIVE HUMIDITY %

26

Atmospheric conditions
High Temperature

Average Penetration Inches / Year

0.035
0.030
0.025

Closed
System

(Oxygen held in
System)

0.020
0.015

Open System
(Oxygen Free to
Escape)

0.010
0.005
0.005

10

20

30

40

50

60

70

80

90

100

110 120 130 140 150 160 170 180

Temperature 0C

27

Types of Corrosion on
Aircraft

Surface
Corrosion:

Fretting Corrosion:

Dissimilar Metal
Corrosion:

Crevice
Corrosion:

Intergranular Corrosion:

Exfoliation
Corrosion:

Filiform
Corrosion:

Stress Corrosion:

Microbiological
Corrosion:
15

Surface Corrosion

16

Filiform corrosion

17

Dissimilar Metal Corrosion

Copper
Iron
Copper

Zinc

Copper

Zinc
Iron
Copper

18

Intergranular Corrosion

Intergranular
Corrosion:

19

Exfoliation
Corrosion:

20

Stress
Corrosion:

21

Fretting Corrosion

22

Crevice
Corrosion:

15

Crevice
Corrosion:

24

Microbiological
Corrosion:

Attaches as brown deposit at the bottom of the

tank

15

Microbiological
Corrosion:

Damp Fungi contribute

corrosion
materials like cotton,
feathers and leather act
as nutrients

micro-organisms
secrete corrosive
fluids

15

Preventive Maintenance

27

Inspection
Spillage of Acid

Battery Compartments

45

Inspection
Alkali spillage

46

Inspection
Mercury
spillage

Before

After

47

Aircraft Cleaning

31

Cleaning & Paint

Removal

31

Protective
Paint Finishes

34

Corrosion
Removal

34

39

Chemical Cleaners
Cleaning Material Selection

Strips multiple layers of

Paint and Primer from

metals

General Purpose
Cleaner detergent.
Removes grease, oil
and tough soils..

Dry Cleaning solvents

remove almost
anything

32

Chemical Cleaners
Cleaning Material Selection

Safety Solvent

Aliphatic Naphtha

Aromatic
Naphtha

Tri-chloro-ethane

MethylChloroform

32

Chemical Cleaners

Cleaning Material Selection

Kerosene

isopropyl
alcohol

MethylEthylKetone
(MEK)

anhydrousethyl
alcohol

32

Chemical Cleaners
Cleaning Material Selection

carbon
tetrachloride

PhosphoricCitricAcid
mixture

Chlorinatedsolvent

BakingSoda

32

Soaps and Detergent Cleaners

Soaps

cleaningcompoundfor
Aluminumsurfaces

Detergent
NonionicDetergent40
Cleaners

Emulsion Cleaners

SolventEmulsion
Cleaner

EmulsionCleaners

WaterEmulsionCleaner
41

Mechanical Cleaning Materials

Powdered
pumice

Impregnatedcotton
wadding

Aluminummetalpolish
NonwovenAbrasivePads
42

Powerplant Cleaning

Inspection

waste fluid sumps

43

Typical Corrosion Treatment

Corrosion Removal

44

Corrosion Removal

45

Corrosion on High Stressed Steel

Components

46

Identification of
metals

48

Corrosion on Ferrous
Metals

35

On Aluminum & Magnesium

Aluminum
Magnesium

Aluminum

Magnesium
7

Aluminium
Alloys

50

ALCLA
D

38

Magnesium
Alloys

48

On Copper & Its Alloys

Greenish film forms on Copper and its alloy

8

Bronzes

48

Treatment of Titanium and Titanium Alloys

55

Permanent Anti-Corrosion
Treatments

56

Mechanism
Galvanic Series

11

Electro-Plating

41

Anodizing

59

Passivation

44

Phosphating

44

Chromating

44

Sprayed Metal
Coatings

42

THE END

49