CORROSION

CORROSION is a natural phenomenon which attacks metal

by chemical or electrochemical action and converts it into a
metallic compound. The corrosion occurs because of the
tendency of metals to return to their natural state.
• Steel:
Corrosion of steel is easily recognized because the corrosion
product is red rust.
• Aluminum:
Aluminum and its alloys exhibit a wide range of corrosion
such as crevice, stress, and fretting corrosion
Four Conditions must exist for corrosion
to start
Causes of Corrosion
Types of Corrosion
INTERGRANULAR CORROSION
• STRESS CORROSION - Stress corrosion cracking is an inter-granular
cracking of the metal which is caused by a combination of stress and
corrosion. Stress may be caused by internal or external loading.
Internal stress are produced by non-uniform deformation during cold
working, by unequal cooling from high temperatures, and by internal
structural rearrangement involving volume changes.
FATIGUE CORROSION - Fatigue corrosion is caused by the combined effects of cyclic
stress and corrosion.
Electrode Potential of Metals

ANODIC – will give up electrons (corrode easily)

CATHODIC – least to corrode
Corrosion Inspection
• Visual inspection
• Magnifying glass,
• Mirrors,
• Borescope, fibre optics,
• Dye penetrant inspection
• Ultrasonic inspection
• Pulse-echo method
• Resonance method
• Eddy current inspection
• X-ray inspection
SEALANT COMPOUND
SEALANTS – used to contain fuel, maintain cabin pressure, reduce fire hazards,
exclude moisture, prevent corrosion, and fill gaps and smooth discontinuities
on the aircraft exterior.

SEALING – is a process that confines liquids and gases within a given area or
prevents them from entering areas from which they must be excluded.
Categories of Compounds
Sealing compounds are divided into two categories, silicone and nonsilicone.
• 1.Silicone compounds – are usually white, red, or grey in colour and are used in
general where heat resistance is required.
• 2.Nonsilicone compounds – can be any colour and are used where heat
resistance is not required.
Specification / Classification
The classification system for sealants in Boeing material specifications (BMS.s)
is as follows:
• Class A – Brush coat Sealant. (Thinned with solvent to provide viscosity suitable
for brushing).
• Class B – Filleting Sealant. (Relatively heavy consistency with good thixotropic
(low-slump) properties).
• Class C – Faying Surface Sealant. (Medium consistency for good spreadability).
• Class D – Hole-Filling Sealant. (Similar to Class B but with very low slump).
• Classes E and F – Sprayable sealant
PROPERTIES OF COMPOUNDS
• Application Time
• Is the time in hours after thawing
• Squeeze-out Life
during which the sealant can be • Is the time in hours after
readily extruded from the sealant thawing during which a
gun and applied to the structure. faying surface sealant
The application time is not
applicable to one-part sealants.
can be squeezed out of a
joint when fasteners are
Note: The application time is included installed.
in the BMS classification system as a
dash number following the Note: The squeeze-out life is
classification letter (except Class C). included in the BMS
Ex. Class B-2 means fillet sealing
material has a minimum application
classification system as a
time of 2 hrs. dash number following the
Class C designation.
PROPERTIES OF COMPOUNDS
• Tack-free Time
• Is the time in hours after thawing
that is required for the sealant to
cure sufficiently so that it will not
transfer to finger or to a plastic
film.
Note: If the temperature of the sealant
exceeds 120 deg-F bubbling will
occur.
• Cure Time
• Is the time in hours after thawing
that is required for the sealant to
cue firmly enough to be handled
without damage or deformation.
After cure time has elapsed,
manufacturing operations such as
drilling and fastening can be
performed without damage to
the sealant.
Non-Destructive Testing (NDT)
• 1. Visual Inspection
• 2. Tap Test
• 3. Liquid Penetrate Inspection
• 4. Magnetic Particle Inspection
• 5. Eddy Current Inspection
• 6. Ultrasonic Inspection
• 7. X-ray Inspection