Treatment of Installed Magnesium Castings

Magnesium castings, in general, are more porous and more prone to penetrating attack than wrought magnesium skins. For all practical purposes, however, treatment is the same for all magnesium areas. Engine cases, bellcranks, fittings, numerous covers, plates, and handles are the most common magnesium castings.

When attack occurs on a casting, the earliest practicable treatment is required if dangerous corrosive penetration is to be avoided. In fact, engine cases submerged in saltwater overnight can be completely penetrated. If it is at all practicable, parting surfaces should be separated to effectively treat the existing attack and prevent its further progress. The same general treatment sequence in the preceding paragraph for magnesium skin should be followed.

If extensive removal of corrosion products from a structural casting is involved, a decision from the manufacturer may be necessary to evaluate the adequacy of structural strength remaining. Specific structural repair manuals usually include dimensional tolerance limits for critical structural members and should be referred to, if any question of safety is involved.

Treatment of Titanium and Titanium Alloys

Attack on titanium surfaces is generally difficult to detect. Titanium is, by nature, highly corrosion resistant, but it may show deterioration from the presence of salt deposits and metal impurities, particularly at high temperatures. Therefore, the use of steel wool, iron scrapers, or steel brushes for cleaning or for the removal of corrosion from titanium parts is prohibited.

If titanium surfaces require cleaning, hand polishing with aluminum polish or a mild abrasive is permissible, if fiber brushes only are used and if the surface is treated following cleaning with a suitable solution of sodium dichromate. Wipe the treated surface with dry cloths to remove excess solution, but do not use a water rinse.

Protection of Dissimilar Metal Contacts

Certain metals are subject to corrosion when placed in contact with other metals. This is commonly referred to as electrolytic or dissimilar metals corrosion. Contact of different bare metals creates an electrolytic action when moisture is present. If this moisture is salt water, the electrolytic action is accelerated. The result of dissimilar metal contact is oxidation (decomposition) of one or both metals. The chart shown in Figure 6-18 lists the metal combinations requiring a protective separator. The separating materials may be metal primer, aluminum tape, washers, grease, or sealant, depending on the metals involved.

Contacts Not Involving Magnesium

All dissimilar joints not involving magnesium are protected by the application of a minimum of two coats of zinc chromate or, preferably, epoxy primer in addition to normal primer requirements. Primer is applied by brush or spray and allowed to air dry 6 hours between coats.

Contacts Involving Magnesium

To prevent corrosion between dissimilar metal joints in which magnesium alloy is involved, each surface is insulated as follows:

At least two coats of zinc chromate or, preferably, epoxy primer are applied to each surface. Next, a layer of pressure sensitive vinyl tape 0.003 inch thick is applied smoothly and firmly enough to prevent air bubbles and wrinkles. To avoid creep back, the tape is not stretched during application. When the thickness of the tape interferes with the assembly of parts, where relative motion exists between parts, or when service temperatures above 250 °F are anticipated, the use of tape is eliminated and extra coats (minimum of three) of primer are applied.

Corrosion Limits

Corrosion, however slight, is damage. Therefore, corrosion damage is classified under the four standard types, as is any other damage. These types are: (1) negligible damage, (2) damage repairable by patching, (3) damage repairable by insertion, and (4) damage necessitating replacement of parts.

The term “negligible," as used here, does not imply that little or nothing should be done. The corroded surface should be cleaned, treated, and painted as appropriate. Negligible damage, generally, is corrosion that has scarred or eaten away the surface protective coats and begun to etch the metal. Corrosion damage extending to classifications of “repairable by patching" and “repairable by insertion" should be repaired in accordance with the applicable structural repair manual. When corrosion damage exceeds the damage limits to the extent that repair is not possible, the component or structure should be replaced.

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