Types of Corrosion Covered in Chapter 8

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Chapter 8 : Cleaning and

Corrosion Control
1
Chapter 8 : Cleaning and Corrosion
Control
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Type of Corrosion
• Corrosion is a very general term and may appear
variety of forms, on the metal involve and the corrosion-
producing agents present As a A&P technician. you must be
familiar the different types of corrosion as well as how to
identify each.
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Type of Corrosion
OXIDATION
One of the simpler forms of corrosion is "dry"
corrosion or, as it is most generally known, oxidation. When a
metal such as aluminum is exposed to a gas containing
oxygen, a chemical reaction takes place on the surface
between the metal and the gas.
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Type of Corrosion
OXIDATION
Two aluminum atoms join three oxygen atoms to form
aluminum oxide (AL2O3). If the metal is iron or steel, two
atoms of iron join three atoms of oxygen to form iron oxide.
or rust (Fe2O3) .
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Type of Corrosion
OXIDATION
There is one big difference between
iron oxide and aluminum oxide. The film of
aluminum oxide is unbroken and, therefore,
once it has formed, further reaction with
oxygen slows dramatically. Iron oxide, on the
other hand, forms a porous, interrupted film.
Since the film is not air tight, the metal
continues to react with the oxygen in the air
until the metal is completely eaten away.
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Type of Corrosion
OXIDATION
The best way to protect iron from dry corrosion is to
keep oxygen from coming into contact with its surface. This
is done temporarily by covering the surface with oil or
grease, or permanently with a coat of paint.
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Type of Corrosion
OXIDATION
Aluminum alloy can be protected from oxidation by
the formation of an oxide film on its surface. This film
insulates the aluminum from any electrolyte and prevents
further reaction with oxygen. The protection afforded by an
aluminum oxide coating is the principal reason for cladding
(Alclad) aluminum alloy used in structural applications.
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Type of Corrosion
UNIFORM SURFACE CORROSION
• Where an area of unprotected metal is exposed
to an exhaust atmosphere containing battery fumes
gases, or industrial contaminants, a uniform attack over
the entire surface occurs.
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Type of Corrosion
• This dulling of the surface is caused by
microscopic amounts of the metal being converted into
corrosion salts. If these deposits are not removed and the
surface protected against further action, the surface
becomes so rough that corrosion pits form.
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Type of Corrosion
Corrosion sometimes
spreads under the surface and
cannot be recognized by either
roughening of the surface or by a
powdery deposit. Instead, the
paint or plating lifts off the surface
in small blisters due to the
pressure of the underlying
accumulation of corrosion
products.
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Type of Corrosion
• A common type of uniform surface
corrosion is caused by the reaction of metallic
surfaces with atmospheric contaminants.
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Type of Corrosion
• These include airborne chlorine or sulphur
compounds, oxygen, or moisture in the atmosphere.
Reactive compounds from exhaust gases, as well as
fumes from storage batteries, frequently cause
uniform surface corrosion.
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Type of Corrosion
PITTING CORROSION
• Pitting is a likely result of uniform surface
corrosion left untreated. Pits form as localized and
corrosive action continues until an appreciable
percentage of the metal thickness is converted into salts.
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Type of Corrosion
PITTING CORROSION
• In extreme cases, this can eat completely through the
metal. Pitting corrosion is usually detected by the
appearance of clumps of white powder on the surface.
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Type of Corrosion
PITTING CORROSION
• The pits found in this type of corrosion usually have a
rather short, well-defined edge with walls that run almost
perpendicular to the surface of the metal. All forms of pits
have one thing in common, regardless of their shape. They
penetrate deeply into the metal and cause damage
completely out of proportion to the amount of metal
consumed.
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Type of Corrosion
PITTING CORROSION
• A metal's protective coating must be
removed or penetrated before the destructive
chemical action leading to pitting can occur.
However, once pitting begins, it is propagated
by means of concentration cells or
galvanic action .
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Type of Corrosion
GALVANIC CORROSION
• This common type of corrosion occurs any time
two dissimilar metals make electrical contact in the
presence of an electrolyte. For example, gal corrosion
can take place where metal skins are riveted together, or
where al inspection plates are attached to the structure
steel screws
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Type of Corrosion
GALVANIC CORROSION
When metals of the same galvanic grouping are joined
together, they show little tendency for galvanic corrosion. But metals
of one group corrode when they are held in contact with those in
another . The further apart the groups, the more active the corrosion.
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Type of Corrosion
GALVANIC
• CORROSION
• In addition, corrosion is much more rapid when the anodic
metal is smaller than that of the cathodic metal. The reason for this
is the greater area of the cathode allows a higher rate of electron
flow, accelerating the speed of the reaction. On the other hand, if
the corroding metal (anode) is larger than the less active metal
(cathode) corrosion is slow and superficial.
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Type of Corrosion
CONCENTRATION CELL CORROSION
• Concentration cell corrosion, or Crevice corrosion
is corrosion of metals in a metal-to-metal joint, corrosion
at the edge of a joint even though the metals are identical,
or corrosion of a spot on a metal's surface covered by a
foreign material.
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Type of Corrosion
1.OXYGEN
CONCENTRATION
CELL CORROSION
CONCENTRATION 2.METEAL ION

CELL CORROSION CONCENTRATION
CELL CORROSION
3.ACTIVE-PASSIVE
CELLS
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Type of Corrosion
OXYGEN CONCENTRATION CELL CORROSION
• When water covers the surface of an aluminum
aircraft skin and seeps into the cracks between lap joints,
oxygen concentration cell corrosion can form. Since water
in an open area readily absorbs oxygen from the air, it
attracts electrons from the metal to form negative
hydroxide ions.
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Type of Corrosion
• The electrons required to form these negative
ions come from the metal itself The area between the
skins does not give up electrons to the water on its
surface because there is not enough oxygen there to
hydroxide ions.
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Type of Corrosion
• Instead, its electrons flow to area the cathodic surface
the open area. The area between the skins, having lost
electrons, now contains positive aluminum ions, and this
area becomes the anode.
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Type of Corrosion
• Electrons flow within the metal from the anode to
in the area e cathode, leaving positive metal aluminum
between These positive the water attract the sheets.
The unusual characteristic where there and the
aluminum of Corrosion is that it forms in the areas
where there is a deficiency of oxygen.
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Type of Corrosion
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Type of Corrosion
• Oxygen concentration cell
corrosion can occur on aluminum,
magnesium, or on ferrous metals.
It forms under marking tape of
ferrules on aluminum tubing,
beneath sealer that has loosened,
and under bolt or screw heads.
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Type of Corrosion
• When dirt or other oxygen-excluding
contamination forms on an anodized surface and the
oxide film is scratched, oxygen concentration cell
corrosion can prevent the protective film from
reforming.
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Type of Corrosion
METEAL ION CONCENTRATION CELL CORROSION
• The electrode potential within a metal is dependent on

the difference metals that up make up the alloys.
However, a potential difference can occur if an electrolyte
having a nonuniform concentration of metal ions covers
the surface.
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Type of Corrosion
• For example, some metal to metal joints rub against each

other creating a high concentration of metal ions adjacent to a
low concentration of metal ions.
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Type of Corrosion
• As with oxygen concentration cell corrosion, when

water absorbs oxygen, it attracts electrons. When these
electrons leave the aluminum to form negative hydroxide
ions, positive aluminum ions are formed. The water can
move freely on the surface of the metal, and this
movement continually carries the aluminum ions away.
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Type of Corrosion
• However, the water between the two pieces of metal

does not move, and it therefore has a higher
concentration of metal ions than there is in the open.
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Type of Corrosion
• The metal area between the faying surfaces, where the

concentration of positive metal ions is the highest,
becomes the cathode and attracts electrons from the
skin in the open area, which is the anode.
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Type of Corrosion
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Type of Corrosion
• As electrons flow from the anode to the cathode they

leave positive aluminum ions on the surface near the
supply of negative hydroxide ions. These hydroxide ions
join the aluminum ions to form aluminum hydroxide, a
corrosion salt.
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Type of Corrosion
• Note the difference between the two types of con

centration cell corrosion. The metallic ion concentration
cell corrosion forms on the open surface, while oxygen
concentration cell corrosion forms in the closed areas
between the faying surfaces. Corrosion on aircraft is
usually complex and is generally composed of more than
one type.
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Type of Corrosion
CONCENTRATION CELL CORROSION
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Type of Corrosion
ACTIVE-PASSIVE CELLS
• Metals film which depend on a tightly adhering for corrosion
passive protection, such as corrosion resistant steel, are prone to
rapid corrosive attack by active-passive cells. The corrosive action
usually starts as an oxygen concentration cell. example, As an salt
deposits on a metal surface in the presence of water containing
oxygen can create the oxygen cell.
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Type of Corrosion
ACTIVE-PASSIVE CELLS
• If the passive film is broken beneath a salt deposit, the active
metal beneath the film will be exposed to corrosive attack. An
electrical potential develops between the large area of the cathode
(passive film) and the small area of the anode (active metal).
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Type of Corrosion
FILIFORM CORROSION
• Filiform corrosion is a special form of oxygen

concentration cell corrosion or crevice corrosion which occurs
on metal surfaces having an organic coating system. It is
recognized by its fine threadlike lines under a polyurethane
enamel finish. Filiform corrosion often results when the wash
primer used on a metal has not been properly cured.
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Type of Corrosion
FILIFORM CORROSION
• A wash primer is a
two-part metal preparation material
in which phosphoric acid converts
the surface of the metal into
a phosphate film that protects
the from corrosion and provides an excellent bond for paint.
• This conversion process relies on moisture in the air and,if there is
not enough moisture to convert all of the acid,some acid remain on
the metal.If a dense polyurethane finish is then applied,the acid
become trapped and react with the aluminum alloy to form corrosion.
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Type of Corrosion
FILIFORM CORROSION
• Filiform corrosion shows itself as a puffiness under the paint film
and is first noticed around rivet heads and along the lap joints skins.
• There is no cure for filiform corrosion
short of stripping all of the paint,
removing the corrosion, treating the
metal’s surface and refinishing the
aircraft.
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Type of Corrosion
FILIFORM CORROSION
Filiform corrosion can be prevented by storing aircraft in an
environment with a relative humidity below 70 percent, using coating
systems having a low rate of diffusion for oxygen and water vapors and
by aircraft to remove acidic contaminants from the surface, such as
those created by pollutants in the air.
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Type of Corrosion
INTERGRANULAR CORROSION
Intergranular corrosion is an attack along the grain
boundaries of a material. Each grain has a clearly defined boundary
which, from a chemical point of view, differs from the metal within the
grain center. The grain boundary and grain center can react with each
other as anode and cathode when in contact with an electrolyte.
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Type of Corrosion
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Type of Corrosion
Recall from Chapter 7 that heat treatment diffuses an alloying
agent into the parent metal. Also that after the heat treatment process,
the alloy must be quenched promptly after it is removed from the heat
bath. If quenching is delayed for even a few seconds, particles of the
alloying agent precipitate out of the metal matrix and can become quite
large. If quenching is delayed too long, these metal grains can reach a
size that produces areas of dissimilar metals large enough to form
effective cathodes and anodes so that intergranular corrosion can
form.
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Type of Corrosion
Spot or seam welding, through localized heating, can also
cause grain enlargement that leaves the metal susceptible to
intergranular corrosion.
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Type of Corrosion
• With some forms of intergranular corrosion small blisters can occur
beneath the surface
• Since intergranular corrosion occurs within the metal itself, rather
than on the surface, it is quite difficult to detect without ultrasonic or
eddy current equipment. Once found, about the only practical
remedy for intergranular corrosion is replacement of the part.
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Type of Corrosion
•EXFOLIATION CORROSION
• Exfoliation corrosion is an extreme case of
intergranular corrosion. It occurs chiefly in extruded
materials, such as channels or angles, where the grain
structure is more laminar (layer like) than in rolled
sheets or castings. This type of corrosion occurs along
the grain boundaries and causes the material to
separate, or delaminate.
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Type of Corrosion
•EXFOLIATION CORROSION
Exfoliation corrosion is an extreme case of intergranular
corrosion. It occurs chiefly in extruded materials, such as channels or
angles, where the grain structure is more laminar (layer-like) than in
rolled sheets or castings.
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Type of Corrosion
EXFOLIATION CORROSION
This type of corrosion occurs along the grain boundaries and
causes the material to separate, or delaminate. As with other types of
intergranular corrosion, by the time it is evident on the surface, the
metal has been damaged beyond salvage.
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Type of Corrosion
STRESS CORROSION
Stress corrosion occurs when metal is
subjected to a tensile stress in the presence of
a corrosive environment. The stresses in the
metal can come from improper quenching after
heat treatment, or from an interference fit of a
fastener. Stress corrosion can be transgranular
or intergranular in nature. Cracks caused by
stress corrosion grow rapidly as the corrosive
attack concentrates at the end of the crack
rather than along its sides.
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Type of Corrosion
•STRESS CORROSION
Since stress corrosion can occur
only in the presence of tensile stresses,
one method for preventing this type of
corrosion in some heat-treated aluminum
alloy parts is to shot-peen the surface to
provide a uniform compressive stress on
the surface. By doing this, the
compressive stresses must be overcome
by tensile forces before stress corrosion
can form.
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Type of Corrosion
FRETTING CORROSION
When two surfaces fit tightly together
but can move relative to one another, corrosion
occurs. This type of corrosion is the result of the
abrasive wear caused by the two surfaces rubbing
against each other. This rubbing, known as fretting,
prevents the formation of a protective oxide film,
exposing active metal to the atmosphere. By the
time this type of corrosion makes its appearance
on the surface, the damage is usually done and the
parts must be replaced.
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Type of Corrosion
FRETTING CORROSION
Fretting corrosion occurs around rivets in a skin and
is indicated by dark deposits around the rivet head streaming
out behind, giving the appearance of rivet smoking. Rivets
showing this sign of fretting must be drilled out and replaced.
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Causes Of Corrosion
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Causes Of Corrosion
ACIDS AND ALKALIS
Almost all acids and alkalis form
effective electrolytes as they react with
metals to form metallic salts, but some
electrolytes are more active than others.
For example, the sulfuric acid found in
aircraft batteries is especially active in
corroding aluminum. However, a weak
solution of chronic or phosphoric acid is
often used as a surface treatment to
prepare metal for painting.
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Causes Of Corrosion
ACIDS AND ALKALIS
Ferrous metals are subject to damage
from both acids and alkalis, but aluminum is
more vulnerable to strong alkaline solutions
than it is to acids. For example, an aluminum
structure can be severely corroded if it is
allowed to remain in contact with a concrete
floor. Water draws out enough lime from the
cement to form an alkaline solution that
corrodes the aluminum.
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Causes Of Corrosion
SALTS
It is very important to remember that
many compounds other than sodium chloride
fall into the category of salts. In general, salts
are the result of a metallic element combining
with a nonmetal. The resulting compound is
almost always a good electrolyte, and can
promote corrosive attack. Magnesium is
particularly vulnerable to corrosive attack
from an electrolyte formed by salt solutions .
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Causes Of Corrosion
MERCURY
Although it is not commonly found in any quantity
around aircraft, there is a definite possibility that mercury
could be spilled in an aircraft, Hazardous cargos are often
carried in aircraft, and damage from a shifting load can
result in damaged containers and hazardous spills.
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Causes Of Corrosion
MERCURY
Mercury attacks aluminum
by a chemical reaction known as
amalgamation. In this process, the
mercury attacks along the grain
boundaries within the alloy, and in
a very short time completely
destroys it.
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Causes of Corrosion
WATER
Pure water reacts with metals to form corrosion or
oxidation, but water holding a concentration of salts or
other contaminants causes much more rapid corrosion.
Seaplanes are in a continual battle with the elements, and
every precaution must be taken to stay ahead of corrosion
formation.
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Causes of Corrosion
AIR
It is obviously impossible to isolate a structure from the
air in which it exists, but the very presence of air is a factor in
the deterioration of metal.
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Causes of Corrosion
AIR
Marine atmosphere and
air above industrial areas hold large
concentrations of salts. The chemicals
precipitate out of the air and collect on
the surface of an aircraft where they
attract moisture from the air.
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Causes of Corrosion
ORGANIC GROWTHS
For years, water which

condensed in fuel tanks produced
relatively minor corrosion problems.
Small perforated metal
containers of potassium dichromate
crystals protected the fuel tanks by
changing any water into a mild
chromic acid solution, which
inhibited corrosion.
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Causes of Corrosion
ORGANIC GROWTHS
This water contains microscopic
animal and plant life called microbes
These organic bodies live in the water
and feed on the hydrocarbon fuel.
Furthermore, the dark insides of
the fuel tank promote their growth, and
in very short periods of time these tiny
creatures multiply and form a scum
inside the tank.
66
Question
1.What is the purpose of wash primer ?
Answer A wash primer is used to protect the surface of the metal
from corrosion my converting the surface of the metal into the
phosphate film and provide an excellent bond for paint.
67
Question
2.How to prevent a filiform corrosion ?
Answer
It can be prevented by storing aircraft in an environment with a
relative humidity below 70 percent, using coating systems having
a low rate of diffusion for oxygen and water vapors and by aircraft
to remove acidic contaminants from the surface.
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Question
3.What is the equipment that we used for detecting intergranular
corrosion?
Answer
Eddy current equipment.
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Question
4.How to protect iron from oxidation corrosion?
Answer
The best way to protect iron from dry corrosion is to keep oxygen
from coming into contact with its surface. This is done temporarily
by covering the surface with oil or grease, or permanently with a
coat of paint.
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THANK YOU
FOR
YOUR ATTENTION
71

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Page 12-8

Chapter 8 : Cleaning and

CONCENTRATION 2.METEAL ION

• The electrode potential within a metal is dependent on

• For example, some metal to metal joints rub against each

• As with oxygen concentration cell corrosion, when

• However, the water between the two pieces of metal

• The metal area between the faying surfaces, where the

• As electrons flow from the anode to the cathode they

• Note the difference between the two types of con

• Filiform corrosion is a special form of oxygen

For years, water which

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