CHAPTER 2:

CORROSION

LEARNING OUTCOMES:
UPON COMPLETION OF THIS COURSE, STUDENTS SHOULD BE ABLE TO:-

 explain clearly the essential criteria of corrosion and its causes

DEFINITION OF CORROSION
 Corrosion is the integration of metals to it’s salts and oxides due to chemical reactions
 Metal corrosion is the deterioration of the metal by chemical or electrochemical attack
and can take place internally as well as on the surface. As in the rotting of wood, this
deterioration may change the smooth surface, weaken the interior, or damage or loosen
adjacent parts.
 Water or water vapor containing salt combine with oxygen in the atmosphere to produce
the main source of corrosion in aircraft. Aircraft operating in a marine environment or in
areas where the atmosphere contains industrial fumes which are corrosive are
particularly susceptible to corrosive attacks.
 Corrosion can cause eventual structural failure if left unchecked. The appearance of the
corrosion varies with the metal.
 On aluminum alloys and magnesium it appears as surface pitting and etching, often
combined with a grey or white powdery deposit.
 On copper and copper alloys the corrosion forms a greenish film; on steel a reddish rust.
When the grey, white, green, or reddish deposits are removed, each of the surfaces may
appear etched and pitted, depending upon the length of exposure and severity of attack.
 If these surface pits are not too deep, they may not significantly alter the strength of the
metal; however, the pits may become sites for crack development. Some types of
corrosion can travel beneath surface coatings and can spread until the part fails.
TYPES OF CORROSION

 There are two general classifications of corrosion which cover most of the specific forms.
a. Direct chemical attack
b. Electrochemical attack.
 In both types of corrosion the metal is converted into a metallic compound such as an oxide,
hydroxide, or sulphate.
 The corrosion process always involves two simultaneous changes
a. anodic change - the metal that is attacked or oxidized suffers
b. cathodic change -the corrosive agent is reduced
DIRECT CHEMICAL ATTACK

 Direct chemical attack, or pure chemical corrosion, is an attack resulting from a direct exposure
of a bare surface to caustic liquid or gaseous agents. Unlike electrochemical attack where the
anodic and cathodic changes may be taking place a measurable distance apart, the changes in
direct chemical attack are occurring simultaneously at the same point.
 The most common agents causing direct chemical attack on aircraft are:
a. Spilled battery acid or fumes from batteries;
b. residual flux deposits resulting from inadequately cleaned, welded, brazed, or soldered
joints;
c. entrapped caustic cleaning solutions. Spilled battery acid is becoming less of a problem
with the advent of aircraft using nickel-cadmium batteries which are usually closed units.
The use of these closed units lessens the hazards of acid spillage and battery fumes.
 Many types of fluxes used in brazing, soldering, and welding are corrosive and they chemically
attack the metals or alloys with which they are used.
 Therefore, it is important that residual flux be removed from the metal surface immediately
after the joining operation. Flux residues are hygroscopic in nature; that is, they are capable of
absorbing moisture, and unless carefully removed, tend to cause severe pitting.
 Caustic cleaning solutions in concentrated form should be kept tightly capped and as far from
aircraft as possible.
 Some cleaning solutions used in corrosion removal are, in themselves, potentially corrosive
agents, and particular attention should be directed toward their complete removal after use on
aircraft. Where entrapment of the cleaning solution is likely to occur, a noncorrosive cleaning
agent should be used even though it is less efficient.
ELECTROCHEMICAL ATTACK

 An electrochemical attack may be likened chemically to the electrolytic reaction which takes
place in:
a. Electroplating
b. Anodizing
c. Dry cell battery.
 The reaction in this corrosive attack requires a medium, usually water, which is capable of
conducting a tiny current of electricity.
 When a metal comes in contact with a corrosive agent and is also connected by a liquid or
gaseous path through which electrons may flow, corrosion begins as the metal decays by
oxidation.
 During the attack, the quantity of corrosive agent is reduced and, if not renewed or removed,
may completely react with the metal (become neutralized). Different areas of the same metal
surface have varying levels of electrical potential and if connected by a conductor, such as salt
water, will set up a series of corrosion cells and corrosion will commence.
 All metals and alloys are electrically active and have a specific electrical potential in a given
chemical environment. The constituents in an alloy also have specific electrical potentials
which are generally different from each other.
 Exposure of the alloy surface to a conductive, corrosive medium causes the more active
metal to become anodic and the less active metal to become cathodic, thereby establishing
conditions for corrosion. These are called local cells.
 The greater the different in electrical potential between the two metals, the greater will be
the severity of a corrosive attack, if the proper conditions are allowed to develop.
 As can be seen, the conditions for these corrosion reactions are a conductive fluid and
metals having a difference in potential. If, by regular cleaning and surface refinishing, the
medium is removed and the minute electrical circuit eliminated, corrosion cannot occur;
this is the basis for effective corrosion control.
 The electrochemical attack is responsible for most forms of corrosion on aircraft structure
and component parts.
 Microbiological Stress
corrosion corrosion

Galvanic corrosion Pitting corrosion

Filiform corrosion Intergranular corrosion

FORMS OF
CORROSION

Surface corrosion Crevice corrosion

Fretting
corrosion Exfoliation
corrosion
 Usually visible as pitting.

 Often referred to as dissimilar metal corrosion.

 Causes by: -

o In the presence of a conducting solution.

o Electron flow occurs between different metals.

o Between different points or areas on a metal surface exhibiting different

electrical potential.
 Occurs in integral fuel tanks
 Caused by the presence of bacteria and fungus in aviation kerosene
 Fungus grows at the fuel/ water interface and the metabolic products formed
corrode the metallic structure.
 Stress corrosion occur when a metal is subjected to stresses applied by
external loads or internal stress caused during manufacture
 It can be indicated by fine cracks
 Stress accelerate the spread of intergranular corrosion and failure of the
affected part may occur without warning.
Stress Corrosion
This type of corrosion occurs following the local breakdown of natural or
applied protective film.

Corrosion cause the pits to deepen but not widen to any great extent.

Pitting corrosion is difficult to detect. If it increase rapidly it can lead to high

local stresses causing mechanical failure.

Pitting Corrosion of
a 7075-T73 Forging
INTERGRANULAR OR INTER CRYSTALLINE CORROSION
 The corrosion occurs within the metal and is caused by areas of potential difference within
the metal grain.
 Such areas are most likely to be found in alloy.
 Corrosion take places along the grain boundaries

CAUSES OF INTERGRANULAR CORROSION

 Improper heat treatment
 Welding (welding decay)

EVIDENCE OF ATTACK
 In severe case it may show up as fine cracks.
 Blisters on aluminum forging
 Example of Intergranular Corrosion

Intergranular corrosion of a failed aircraft

component made of 7075-T6 aluminum
 Crevices in or between components may trap impurities thereby
causing a difference in electrode potential to exist between two
similar metals.

 This results in electro chemical reaction and subsequent corrosion of

materials.
 Example of Crevice Corrosion

Popped rivets were recently found on View of fuselage showing damage to

an external section of a maritime patrol protective coating
aircraft fuselage
 Example of Crevice Corrosion

Underside of panel where severe Close-up picture showing the severity of

corrosion was found corrosion
 Is a form of intergranular corrosion.

 It is often found on extruded aluminum alloy members.

 This type of corrosion causes the metal to separate or delaminate.

 Corrosion products building up along these grain boundaries exert pressure between the
grains and the end result is a lifting or leafing effect.

 Aluminum alloys that have been extruded or otherwise worked heavily, with a microstructure
of elongated, flattened grains, are particularly prone to this damage.
 The damage often initiates at end grains encountered in machined edges, holes or
grooves and can subsequently progress through an entire section.

 In this particular form of intergranular corrosion the expansive force of insoluble

corrosion products tends to force the grains apart and leads to exfoliation
corrosion, sometimes known as lamellar or layer corrosion. In extreme cases, the
edges of the affected area are leaf like and resemble the separated pages of a
wetted book that has become swollen and begun to open up.

Exfoliation Corrosion of
7075-T6 Fuselage Stringers
 Fretting corrosion refers to corrosion damage at the asperities of contact surfaces. This
damage is induced under load and in the presence of repeated relative surface motion,
as induced for example by vibration.
 Occurs between moving parts under very high surface loads
 Pits or grooves and oxide debris characterize this damage, typically found in machinery,
bolted assemblies and ball or roller bearings. Contact surfaces exposed to vibration
during transportation are exposed to the risk of fretting corrosion.
 Movement causes the breakdown of the protective film to cause oxidation and metal
erosion.

EVIDENCE OF ATTACK
 On Steel – Formation of brown powder
 Aluminum – Formation of black powder

Prevention
 Application of protective coating
 e.g. cadmium plating Fretting Corrosion on F-16
 Restricting the free movement by correct torque loading. Aircraft Main Fuel Shutoff
Valve
 Caused by oxygen in the atmosphere and accelerated by direct chemical
attack from impurities in the atmosphere

 Normally the attack is uniform and slowly reduces the cross-section of the
metal

 A mild attack may lead to slight roughing of the surface

 These are the factors that affect the type, speed, cause and seriousness of metal corrosion:
a. Acids and Alkalis
o All acids and alkalis react with metal to form metallic salts (corrosion), though
some are more active than others
b. Salt
o Marine atmosphere and air above some of the industrial areas hold a large
concentration of salts, which can caused corrosion.
c. Water
o Pure water will react with metals causing corrosion or oxidation.
o But water holding a concentration of salts or other contaminants will cause
much more rapid corrosion.
d. Air
o Naturally the presence of the air is a factor in the deterioration of the metal.
That caused corrosion.
 e. Mercury
o Spilled mercury, as it is ‘slippery’ and will flow through even a tiny crack to get
to the lowest part of the structure where it can cause extensive damage due to
a chemical reaction known as amalgamation.

f. Organic Growths
o The organic bodies live in the water and feed on the hydrocarbon fuel and
corrosion is likely to formed.
o Potassium dichromate crystals can protect the fuel tank.

 Some of those factors can be controlled and some cannot.

 MOISTURE ATMOSPHERE IMPURITIES

 Such as carbon, sulphur and salt when

 Free oxygen in MOISTURE laden
atmosphere will cause oxide films to form
dissolved in moisture form electrolytes

on unprotected metals. (ACIDS or ALKALIS) which promotes

electro-chemical reaction.

CONDITIONS CAUSING CORROSION

DISSIMILAR METALS HEAT

 Dissimilar metals in contact or in close proximity  Parts which become heated in service
to each other causing electro-chemical reaction tends to corrode more readily than those
in thepresence of an electrolyte. not in contact with heat source.
 The basic factor of material and assembly that causes corrosion are: -
a. Selection Of Materials
o For subsequent work repairs and selection of materials by the manufacturer.

b. Dissimilar Metals
o The contact of dissimilar metals, which occurs in many parts of aircraft structures
and in most accessory components, is always likely to cause electro-chemical
reaction.

c. Heat Treatment
o Incorrect heat treatment may lower the corrosion resistance of the material treated.
o Thus it is essential that all heat treatment should be applied strictly in accordance
with approved specification.

d. Welding
o Welded joints are sometimes subject to corrosion because the heated strip has been
rendered anodic to the surrounding metal.
o But the danger can be greatly reduced by exercising proper skill and care.
e. Fretting
o This is a type corrosion, which can have serious consequences, as it reduces the
fatigue strength of the structure.
o It occurs when parts are bolted tightly together and yet slip slightly on one another
during flexing or other movements of aircraft parts.

f. Stress
o Metals under stress generally corrode more rapidly than unstressed metals.

g. High Temperature
o Parts, which become heated in service, such as brake drums, combustion chambers
and exhaust pipes, tend to oxidise more rapidly than unheated parts.

h. Electrical Equipment
o Faults in the insulation of electrical equipment which lead to current leakage can
cause the equipment itself to:
• corrode
• encourage electro-chemical attack in the surrounding structure
 The type of corrosion attack start on the surface of the metal.
 The terminology used in describing corrosion is based on either:
o The appearance of the corrosive attack
o The mechanism associated with its formation.
 Evidence of corrosion will be indicated in the following manner:

ALUMINIUM ALLOY
 Corrosion of aluminium surface is usually indicated by whitish powdery deposit
with dulling of the surface on unpainted parts.

 The white powdery deposit will forms at:

o Discontinuities in protective coating

o And may spread beneath paint causing blistering or flaking.

 As the corrosion attack advances, the surface will appear mottled or etched with
pitting.

 Swelling or bulging of skins, pulled or popped rivets are often visual indications of
corrosion.
FERROUS METALS

 Form RED powder ferrous oxide crust.

Mild Steel
Plate

Evidence of Corrosion
On Ferrous Metal

Ferrous Oxide
COPPER AND IT'S ALLOYS

 Produce blue-green salts.

Evidence of Corrosion On Copper and It’s Alloy

 Aluminium and Magnesium Alloys

Produce powdery deposits varying in colour

between white and grey.

The products of corrosion of common metals can be

identified by their oxide deposits.

Ferrous Metals Copper and its alloys

Form RED powder produce blue-green salts.

ferrous oxide crust.
 EFFECTS OF CORROSION
ON METALS

 Iron, steel, magnesium and aluminium alloys when attacked will CORRODE and
form powdery deposits.
 Some metal will become TARNISHED. A film forms on the metal to form a barrier.

 For examples : COPPER, BRASS, BRONZE

 Certain metals will form an almost invisible film which form good protective barriers.
 Examples : Tin, Lead, Zinc, Aluminium, Nickel & Chromium
Q & A

EASA
MODULE 6
Q: What does CRES means
A: Corrosion Resistance Stainless Steel
Q: Red powder is the metal oxide deposits for A: Ferrous metals
Q: Which metals corrode easily – more noble or less noble
A: Less noble
Q: Corrosion in a form of worm like trace beneath the paint is a
A: Filiform corrosion
Q: How does a CRES being identified in a bolts head
A: Raised dash
Q: The integration of metals to its salts and oxides is termed as
A: Corrosion
Q: Between magnesium, copper and lead, which one is anodic to
aluminium alloy
A: Magnesium
Q: Corrosion due to improper heat treatment is
A: Intergranular corrosion