Pipe thread type grease fittings

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rod ends

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CORROSION

1. Corrosion and Rust

Corrosion is the deterioration of a metal as a result of chemical reactions between
it and the surrounding environment.
Rust is composed of iron oxides. In colloquial usage, the term is applied to red
oxides, formed by the reaction of iron and oxygen in the presence of water or air
moisture. The most common example of corrosion is, of course, rust. The reddishbrown compound referred to as rust is actually iron oxide (Fe2O3), a result of
reactions between oxygen and iron.

Rust
2. Appearance of the Corrosion
Corrosion can cause eventual structural failure if left unchecked. The appearance of the corrosion
varies with the metal.
a. On aluminum alloys and magnesium it appears as surface pitting and etching, often
combined with a grey or white powdery deposit.
b. On copper and copper alloys the corrosion forms a greenish film;
c. On steel a reddish rust.
3. Glossary of Terms
Battery: An electrochemical device for storing and supplying electrical
energy
Current : The rate of flow electricity. The movement of electrons along a
conductor. The unit of measurement is an ampere.
Electrolyte : In a lead acid battery, the electrolyte is sulfuric acid diluted
with water. It is a conductor and is also a supplier of hydrogen and sulfate
ions for the reaction.
EMF : Potential causing electricity to flow in a closed circuit.
Electron : That part of an atom having a negative charge.
Charge : The conversion of electrical energy from an external source into
chemical energy within a cell or battery.
Cathode: A 'Cathode' is a Negatively charged Electrode (or Element) that attracts
the
Positive (+) ions (Cations) in a Circuit or Chemical reaction
Anodes and cathodes are the end points or terminals of a device that produces
electrical current. Electrical current runs from the positively charged terminal to the
negatively charged terminal. The cathode is the terminal that attracts cations, or
positive ions. To attract the cations, the terminal must be negatively charged.

Electrical current is the amount of charge that passes a fixed point per unit time.
The direction of the current flow is the direction a positive charge would go.
Electrons are negative, and will move in the opposite direction of current

Electroplating: It is a process in which a surface is covered

by a thin layer of another metal. The process of producing a
coating, usually metallic, on a surface by the action of electric current.

Direct Chemical Attack

Direct chemical attack, or pure chemical corrosion, is an attack resulting from a direct exposure
of a bare surface to caustic liquid or gaseous agents.
Electrochemical Attack
An electrochemical attack may be likened chemically to the electrolytic reaction which takes
place in electroplating, anodizing, or in a dry cell battery.
4. FORMS OF CORROSION
There are many forms of corrosion. The form of corrosion depends on the metal involved, its
size and shape, its specific function, atmospheric conditions, and the corrosion-producing agents
present. Those described in this section are the more common forms found on airframe
structures.
A. Surface Corrosion
Surface corrosion appears as a general roughening, etching, or pitting of the surface of a metal,
frequently accompanied. by a powdery deposit of corrosion products. Surface corrosion may be
caused by either direct chemical or electrochemical attack. Sometimes corrosion will spread
under the surface coating and cannot be recognized by either the roughening of the surface or
the powdery deposit. Instead, the paint or plating will be lifted off the surface in small blisters
which result from the pressure of the underlying accumulation of corrosion products.

Pitting

Pitting is a continuation of surface corrosion. Pitting may be detected by the

appearance of a white powder on the surface of the metal.
B. Galvanic Corrosion/Dissimilar Metal Corrosion

This is one of the most common types of corrosion and will occur when these two
conditions are present.
(1) Two dissimilar metals are connected in such a way as to provide a path for
electron flow.
(2) their common surface are covered with some material that will serve as electrolyte.
In other words conduct electricity.
Galvanization (or galvanisation) is the process of applying a protective zinc coating to steel or
iron, in order to prevent rusting. The term is derived from the name of Italian scientist Luigi
Galvani. Although galvanization can be done with electrochemical and electrodeposition
processes, the most common method in current use is hot-dip galvanization, in which steel parts
are submerged in a bath of molten zinc.

C. Intergranular Corrosion

This type of corrosion is an attack along the grain boundaries of an alloy and
commonly results from a lack of uniformity in the alloy structure. Aluminum alloy
and some stainless steels are particularly susceptible to this form of electro

chemical attack. The lack of uniformity is caused by changes that occur in the
alloy during heating and cooling. Intergranular corrosion may exist without
visible surface evidence. Very severe intergranular corrosion may some time
cause the surface of a metal to exfoliate .
D. Stress Corrosion
Stress corrosion occurs as the result of the combined effect of sustained tensile stresses and a
corrosive environment. Stress corrosion cracking is found in most metal systems; however, it is
particularly characteristic of aluminum, copper, certain stainless steels, and high-strength alloy
steels (over 240,000 p.s.i.). It usually occurs along lines of cold working and may he
transgranular or intergranular in nature. Aluminum alloy bell cranks with pressed-in bushings
landing gear shock struts with pipe-thread type grease fittings, clevis pin joints, shrink fits, and
overstressed tubing B-nuts are examples of parts which are susceptible to stress corrosion
cracking.

Stress corrosion
E. Fretting Corrosion
Fretting corrosion is a particularly damaging form of corrosive attack which occurs when two
mating surfaces, normally at rest with respect to one another, are subject to slight relative
motion. It is characterized by pitting of the surfaces, and the generation of considerable quantities
of finely divided debris. Since the restricted movements of the two surfaces prevent the debris
from escaping very easily, an extremely localized abrasion occurs. The presence of water vapor
greatly increases this type of deterioration.

Bearing- Fretting corrosion

Scissors-Fretting corrosion

5. Corrosion Preventive
Corrosion preventive maintenance includes the following specific functions:
(I) An adequate cleaning.
(2) Thorough periodic lubrication.
(3) Detailed inspection for corrosion and failure of protective systems.
(4) Prompt treatment of corrosion and touchup of damaged paint areas.
(5) Keeping drain holes free of obstruction.
(6) Daily draining of fuel cell sumps.
(7) Daily wipe-down of exposed critical areas.
(8). Sealing of aircraft against water during foul weather and proper ventilation on warm, sunny
days.
(9) Making maximum use of protective covers on parked aircraft.
After any period during which regular corrosion- preventive maintenance is interrupted, the
amount of maintenance required to repair accumulated corrosion damage and bring the aircraft
back up to standard with usually be quite high.
6. FACTORS AFFECTING CORROSION
Many factors affect the type, specd~ cause. And seriousness of metal
corrosion. Some of these factors can be controlled and some cannot.
a. Climate
The environmental conditions under which an aircraft is maintained and
operated greatly affect corrosion characteristics. In a predominately marine
environment (with exposure to sea water and salt air), moisture-laden air is
considerably more
detrimental to an aircraft than it would he if all operations were conducted in
a dry climate. Temperature considerations are important because the speed
of electrochemical att~ck is increased in a hot, moist climate.
b. Size and Type of Metal
It is a well known fact that some metals wiH corrode faster than others. I t is
a less known fact that variations in size and shape of a metal can indirectly
affect its corrosion resistance.
c. Foreign Material
Among the controllable factors which affect the onset and spread of
corrosive attack is foreign material which adheres to the metal surfaces.
Such foreign material includes;
(I) Soil and atmospheric dust.
(2) Oil, grease~ and engine exhaust residues.
(3) Salt water and salt moisture condensation.

(4) Spilled battery acids and caustic cleaning solutions.

(5) W'elding and brazing flux residues.
It is important that aircraft be kept clean. How often and to what extent an
aircraft should be cleaned depends on several factors, such as location,
model of aircraft, and type of operation.
7.
a.
b.
c.
d.
e.
f.
g.
h.
i.

CORROSION-PRONE AREAS
Exhaust Trail Areas
Battery Compartments and Battery Vent Openings
Bilge Areas
Wheel Well and Landing Gear
Water Entrapment Areas
Engine Frontal Areas and Cooling Air Vents
Wing Flap and Spoiler Recesses
External Skin Areas
Miscellaneous Trouble Areas

Alodine
These coatings provide improved corrosion protection and paint adhesion. Alodine covers
chrome, non-chrome and anodizing technologies, and serves numerous markets including the
beverage industry, architecture, automotive, aerospace, electronics and others.

8. CHEMICAL TREATMENTS
a. Parco Lubrizing
Parco Lubrizing is a chemical treatment for iron and steel parts which converts the surface to a
nonmetallic oil absorptive phosphate coating. It is designed primarily to reduce wear on moving
parts.
The process is a modification of Parkerizing, and consists of a precleaning treatment in which
vapor degreasing, acid pickle, or spray emulsion is used, followed by a 15 minute dip in a
solution of water and 10 percent by volume of Parco Lubrite.
b. Anodizing

Anodizing is the most common surface treatment of nonclad aluminum alloy surfaces.

Anodizing is an electrochemical process that converts the metal surface into a

decorative, durable, corrosion-resistant, anodic oxide finish.

The aluminum alloy sheet or casting is the positive pole in an electrolytic bath in which chromic
acid or other oxidizing agent produces an aluminum oxide film on the metal surface. Aluminum
oxide is naturally protective, and anodizing merely increases the thickness and density of the
natural oxide film. When this coating is damaged in service, it can only be partially restored by
chemical surface treatments. Therefore, any processing of anodized surfaces, including corrosion
removal, should avoid unnecessary destruction of the oxide film.
The anodized coating provides excellent resistance to corrosion. The coating is soft and easily
scratched, making it necessary to use extreme caution when handling it prior to coating it with
primer.
c. Alodizing
Alodizing is a simple chemical treatment for all aluminum alloys to increase their corrosion
resistance and to improve their paint bonding qualities. Because of its simplicity, it is rapidly
replacing anodizing in aircraft work. Alodine is an international brand name for Henkel
Technologies' conversion, anodizing and functional coatings suitable for use on
aluminum, magnesium and other non-ferrous alloys.

The process consists of precleaning with an acidic or alkaline metal cleaner that is applied by
either dipping or spraying. The parts are then rinsed with fresh water under pressure for 10 to 15
seconds. After thorough rinsing, alodine is applied by dipping, spraying, or brushing. A thin, hard
coating results which ranges in color from light, bluish green with a slight iridescence on copper
free alloys to an olive green on copper bearing alloys. The alodine is first rinsed with clear, cold
or warm water for a period of 15 to 30 seconds. An additional 10 to 15 second rinse is then given
in a Deoxylyte bath. This bath is to counteract alkaline material and to make the alodyzed
aluminum surface slightly acid on drying.

d. Cladding is the bonding together of dissimilar metals. It is different from

fusion welding or gluing as a method to fasten the metals together. Cladding

is often achieved by extruding two metals through a die as well as pressing or
rolling sheets together under high pressure.Cladding is the covering of one
material with another.
e. Alclad is a trademark of Alcoa used as a generic term to describe corrosion
resistant aluminium sheet formed from high-purity aluminium surface layers
(appr. 5.5 percent on each side) metallurgically bonded to high strength
aluminium alloy core material. These sheets are commonly used by the
aircraft industry. Alclad is a product having an aluminum or aluminum alloy
coating metallurgically bonded to the surface.Alcoa Inc.: (from Aluminum
Company of America) is the world's third largest producer of aluminum,
behind Rio Tinto Alcan and Rusal