Corrosion Control

Many aircraft structures are made of metal, and the most insidious form of damage to those structures is corrosion. From the moment the metal is manufactured, it must be protected from the deleterious effects of the environment that surrounds it. This protection can be the introduction of certain elements into the base metal, creating a corrosion resistant alloy, or the addition of a surface coating of a chemical conversion coating, metal or paint. While in use, additional moisture barriers, such as viscous lubricants and protectants may be added to the surface.

The introduction of airframes built primarily of composite components has not eliminated the need for careful monitoring of aircraft with regard to corrosion. While the airframe itself may not be subject to corrosion, the use of metal components and accessories within the airframe means the aircraft maintenance technician must be on the alert for the evidence of corrosion when inspecting any aircraft.

This chapter provides an overview to the problems associated with aircraft corrosion. For more in-depth information on the subject, refer to the latest edition of FAA Advisory Circular (AC) 43-4A, Corrosion Control for Aircraft. The advisory circular is an extensive handbook, which deals with the sources of corrosion particular to aircraft structures, as well as steps the aircraft maintenance technician can take in the course of maintaining aircraft that have been attacked by corrosion.

Metal corrosion is the deterioration of the metal by chemical or electrochemical attack. This type of damage 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 combines 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 that are corrosive, are particularly susceptible to corrosive attacks. [Figure 6-1]

If left unchecked, corrosion can cause eventual structural failure. The appearance of corrosion varies with the metal. On the surface of aluminum alloys and magnesium, it appears as pitting and etching, and is often combined with a gray or white powdery deposit. On copper and copper alloys, the corrosion forms a greenish film; on steel, a reddish corrosion byproduct commonly referred to as rust. When the gray, 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, particularly if the part is highly stressed. Some types of corrosion burrow between the inside of surface coatings and the metal surface, and can spread until the part fails.

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