CORROSION

PREVENTION MANUAL

TASK 51-11-01-910-001-A
EFFECTIVITY: ALL
TYPES AND CAUSES OF CORROSION

1. General

A. Corrosion is a phenomenon that occurs in metals as a result of chemical or electrochemical action.

With time and usage, metals go back to a low-energy state and change into metal compounds such as
oxides, hydroxides or sulfates.

B. Because different materials have different characteristics and properties, they can be under the effects
of corrosion. Other factors that cause corrosion are environmental conditions. To prevent or decrease
the effects of corrosion, research on new materials never stops. It is necessary to improve the protec-
tion of metal parts.

C. To understand the procedures for the prevention and control of metal corrosion, it is necessary to
know:

• The appearance and types of corrosion to which the different types of metals are subject.

• The corrosive agents that attack the metal surfaces.

• The areas of the aircraft that are usually under corrosive attack.

• The classification of corrosion levels.

• The different types of repair for each type of material.

D. These are the best procedures for protection against corrosion:

• The use of corrosion-resistant materials.

• Good protection for the materials in the design phase and the service life of the components.

• Cleaning and regular maintenance of the aircraft.

• Immediate identification of corrosion.

• Immediate repair of corroded parts, components and areas.

Even when you take these precautions, corrosion can occur as a result of special climatic conditions or
because of the influence of substances such as salts and contaminants.

2. Causes of Corrosion

A. Corrosion starts when these conditions occur:

• There is a metal subject to corrosion (anode).

• There is a dissimilar conductive material (cathode).

• There is a continuous conductive liquid path (electrolyte).

• There is an electric contact between the anode and the cathode.

B. These are other causes of corrosion:

• The incorrect choice of materials, manufacturing process, and assembly procedures.

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 CORROSION
PREVENTION MANUAL

• The usual operation and maintenance of the aircraft (removal of the protective finish).

• Environmental conditions (seacoast humidity, airborne pollutants).

• Finish deterioration (age and erosion).

• Aircraft operation (animal transportation and seafood shipment).

• Accidental contamination (chemical spills and galley spillage).

3. Corrosive Agents

A. Many fluids used in aircraft maintenance and operation are corrosive. The climate and atmospheric
conditions are also corrosive. The most common corrosive agents are:

(1) Acids.

(a) Sulfuric acid (battery acid) and organic acid (human and animal waste) can cause corrosion
in many alloys.

(2) Alkaline Solutions.

(a) Alkaline solutions can cause corrosion in aluminum alloys. The most common alkaline solu-
tions are washing soda and potash.

(3) Salts.

(a) Salt solutions can attack aluminum alloys and steels. The salt solutions are corrosive
agents because they are good electrolytes.

(4) Corrosive Agents in the Atmosphere.

(a) The two primary corrosive agents in the atmosphere are moisture and oxygen. The environ-
mental conditions, such as those in industrial and marine regions, can increase atmospher-
ic corrosion.

1 Industrial Environment

a The most common agents are oxidized sulfur and nitrogen compounds. When
one of these agents mix with moisture, it becomes a corrosive agent and at-
tacks the aircraft structure.

2 Marine Environment

a Airborne salts in a marine environment is one of the most corrosive agents. This
is because the salt solutions are electrolytes and can cause corrosion in the air-
craft structure.

4. Types of Corrosion

The most common types of corrosion are:

A. Galvanic Corrosion.

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 CORROSION
PREVENTION MANUAL

(1) Maintenance personnel can recognize this type of corrosion because it leaves a deposit of white
or gray powder in metal joints. Galvanic corrosion occurs when two dissimilar metals make con-
tact or when there is an electrolyte between them. For galvanic corrosion to occur, there must be
an anode (a material more subject to corrosion) and a cathode (a material less subject to corro-
sion). A protective finish can decrease the effects and the rate of corrosion. But when a mainte-
nance procedure causes the removal of the protective finish, the galvanic corrosion process can
start again.

B. Crevice Corrosion.

(1) This type of corrosion is severe and occurs locally between interfaying surfaces. Crevice corro-
sion is the result of electrochemical action. This phenomenon occurs in the same way as galvanic
corrosion, where two dissimilar metals act as an anode and a cathode. Water, which has oxygen,
gets into the crevice and becomes an electrolyte. It is difficult to find crevice corrosion in the be-
ginning of the process because it occurs in hidden areas.

(2) Crevice corrosion becomes more severe when it contains salts (usually in seacoast environ-
ments, galleys, lavatories, cargo spills, and human waste).

(3) The use of water-displacing compounds can help prevent this type of corrosion or decrease its
effects. But you must keep the layer of compound in good condition to prevent the start of the
corrosion process.

C. Pitting Corrosion.

(1) Maintenance personnel can recognize this type of corrosion because of the pits (holes) in the
metal surfaces. Pitting corrosion starts when the protective finish is not of the correct type or
when it is damaged. Pitting corrosion can start, go into a given depth, and then stop. This type of
corrosion can cause many small local pits in different areas, with almost no loss of material. So,
the remainder of the metal surface stays in almost good condition. But these pits can spread and
go fully through the metal.

(2) Pitting corrosion usually occurs when erosion or other forms of corrosion starts. Pits (holes) in a
crevice increases at a higher rate than those on a visible surface. It can cause fatigue cracks to
start and spread. The correct protective treatment can prevent or stop this type of corrosion.

D. Exfoliation Corrosion.

(1) This corrosion is of the intergranular type and causes flaking and loss of metal thickness. Exfolia-
tion corrosion occurs because of the swelling and flaking at the grain ends during the manufactur-
ing process. When the machining and chemical milling operations show the end of the grain, ex-
foliation corrosion can occur. To prevent exfoliation corrosion, the metal must receive sufficient
protection. Exfoliation corrosion can cause bulging on the faying surface of skin panels. This will
cause fastener head deformation, pull-through, or failure.

E. Microbiological Corrosion.

(1) Microorganisms can cause this type of corrosion. Maintenance personnel can recognize micro-
biological corrosion because it contains fungi. It looks slimy with a color range from brown to
black. It takes the shape of long threads and forms mats or scattered globules. Contaminated fuel
can cause microbiological corrosion. Microorganisms release metabolic products that attack the
tank finish and corrode aluminum alloys.

F. Fretting Corrosion.

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 CORROSION
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(1) This type of corrosion occurs because of the removal of the protective film on the metal surface.
The bare metal is subject to wear and corrosion because of the movement of the metal surfaces
against each other. This forms layers of dark oxides. Debris and corrosive agents can increase
the corrosion process. Because of this, seizure and cracks can occur at the joints. The cracks at
the joints will spread as a result of cyclic loading.

G. Intergranular Corrosion.

(1) Intergranular corrosion is an attack on the grain boundaries of a metal. Microphotographs show
that aluminum alloys consist of very small grains held together by chemical bonds.

In the heat-treating process, the temperature of the metal increases so much that the alloying el-
ements go into solution with each other. When the temperature of the metal is uniform, the metal
is removed from the furnace and immediately quenched in water. This solidifies the alloying ele-
ments into small grains.

If there is a delay in the quenching procedure, even for a few seconds, the grains will grow. The
grains will grow to such a size that the areas of dissimilar metals will have efficient anodes and
cathodes to start the corrosion process.

If the corrosion gets to the boundary between the large grains through a pit (hole), the corrosion
process can continue in the metal. The electrolyte comes from the corrosion deposits on the met-
al surface and along the grain boundaries while the intergranular corrosion process continues.

(2) Spot welds or seam welds can also make the grains larger and cause intergranular corrosion.
Under the metal surface, there can be blisters removed from the point of initial penetration. The
metal surface over these blisters is very thin. If you lift the metal surface with the point of a knife,
you will see a cavity filled with the salts of corrosion.

(3) Because intergranular corrosion occurs in the metal (not on the surface), it is difficult to find it
without the use of ultrasonic or X-ray equipment. If a part shows signs of intergranular corrosion,
the only correct procedure is to replace the damaged part.

H. Stress Corrosion.

(1) Maintenance personnel can recognize this type of corrosion because the metal shows cracks that
spread quickly. It is a type of intergranular corrosion that starts as a result of residual stresses
from machining or chemical milling operations. The bare metal surface is subject to corrosive at-
tack.

(2) Stress corrosion usually occurs in areas where there are open grains or pits. It can cause the de-
struction of the structural components. The careful choice of materials, correct design, good as-
sembly techniques, and surface protection can prevent this type of corrosion.

5. Areas Where Corrosion Can Occur (Critical Areas)

A. The operator must give special attention to the conditions of the areas where corrosion usually occurs.
These conditions are:

• Cleanliness;

• Frequency of inspection;

• Application of corrosion-inhibiting compounds;

• Treatment of the area where corrosion occurred.

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B. The areas where corrosion usually occurs are:

(1) Bilge Area.

(a) Dirt and contaminants, which can become corrosive agents, usually collect in the bilge
area. They are:

• Hydraulic fluid

• Water

• Chips

• Lost fasteners

(2) Lavatory Area - Including Floor and Underfloor Area.

(a) All areas near the lavatory are subject to spills of fluids (water, cleaning products, etc.), dirt,
and leaks in the lavatory pump line.

(3) Galley Area - Including Floor, Underfloor Area, Drawers, Drawer Track, and Seat Tracks near this
area.

(a) All areas near the galley are subject to spills of fluids (water, cleaning products, beverages,
etc.) which, together with leftovers and dirt, collect on the drawer tracks, in the drawers, and
on the tracks of the passenger seats.

(4) Nose and Main Landing Gear Wheelwells and Doors.

(a) These are some of the areas where corrosion usually occurs because of the direct action of
water, moisture, debris, salts, sand, gravel, and pebbles.

(5) Passenger and Cargo Doors and Surrounding Structure.

(a) During boarding, deplaning, and loading and unloading operations, moisture and rainwater
can get into these areas. Marine and industrial environments can also cause corrosion in
these areas.

(6) Battery Compartment.

(a) The operator must give special attention to this area because it is difficult to prevent battery
acid spillage during servicing. A leak in a damaged battery is also a cause of corrosion.
Spilled battery acid can collect in cavities of the aircraft structure and spread to areas that
do not have good protection.

(7) Skin Areas, Aft Fuselage and Horizontal Stabilizers.

(a) In these areas, corrosion usually occurs at the edges of the skin panels and around the fas-
tener heads. The operator must give special attention to the areas where the maintenance
personnel replaced the fasteners. This is because the fastener holes can become a source
of corrosion. The most common type of corrosion that occurs on skin panel surfaces is the
filiform corrosion.

(8) Fuel Tanks.

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(a) Corrosion in the fuel tank can occur because microorganisms get into it during the filling op-
eration. Water dissolved or suspended in the fuel is also a source of corrosion. Contamina-
tion of the fuel because of microbial growth usually occurs in aircraft that operate in hot,
damp climate.

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