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Types Of Corrosion
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I. Introduction to Corrosion
a) Definition a chemical or electrochemical attack on
metal that changes some of the metal into its salts.
Corrosion weakens primary structural members.
It must be replaced or reinforced to sustain flight
loads.
Corrosion attacks, cost the aviation industry billions
of dollars each year.
The advanced age of many airliners and military
aircraft has made corrosion detection and removal
one of the most important aspects of modern aircraft
maintenance.
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b) Types of Corrosion
There are 2 types of corrosion;
i. Chemical
Pure chemical corrosion result from direct
contact of caustic liquid or gas.
ii. Electrochemical
An electrolytic action which takes place
inside a metal or on its surface. The metal
reacts with electrolyte and part of metal
changed into salt.
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1.Oxidation
One of the simplest forms of corrosion is dry
corrosion or by its common name rust.
Chemical action in which a metallic element is united
with oxygen
Aluminum alloy may be protected from oxidation by
electrolytically or chemically forming a hard oxide film
on its surface. e.g. ALCLAD
This airtight film prevents any air or moisture
reaching the metal and oxide itself will not continue to
react with the oxygen in the air.
The best way to protect iron is by temporarily cover it
with oil or grease or permanently coat it with paint.
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3. Pitting Corrosion
Result of Uniform Surface Corrosion left
untreated.
a localized corrosion which starts at a surface
and progresses into metal.
Usually detected by the appearance of
clumps of white powder on the surface .
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4. Galvanic Corrosion
Occurs any time two dissimilar metals make electrical
contact in the present at an electrolyte.
It can take place where two dissimilar metal skins are
riveted together.
or where aluminum inspection plates are attached to
the structure with steel screws.
The further apart the groups (electrochemical series
for metal), the more active the corrosion
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6. Filiform Corrosion
Consists of threadlike filaments of corrosion that
form on the surface of metals coated with organic
substances such as paint films.
It occur when the wash primer used on a metal has
not been properly cured.
It shows itself as a puffiness under the paint film
and is first noticed around rivet heads and along the
lap joints of skins.
It can be prevented by storing aircraft in an
environment with relative humidity below 70%.
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7. Intergranular Corrosion
Attacks metal along the grain boundaries.
It occur when the metal is not properly heat treated.
Most types of corrosion on aluminum alloys are
intergranular.
Spot welds and seam welds can also leads to this
type of corrosion.
Hard to detect because it is inside the metal.
Ultrasonic and X-ray is needed for this corrosion.
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8. Exfoliation Corrosion
An extreme case of intergranular corrosion
in an extruded metal part such as channels
where the grain structure is laminar (layerlike).
The corrosion causes the metal to separate
in layers or delaminate.
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9. Stress Corrosion
Is a form of intergranular corrosion that forms in a
metal when it is subject to continuous tensile
stress.
Results from improper quenching after heat
treatment or from interference fit of a fasteners.
Common location are at stressed skin around
pressed and bushings and tapered pipe fittings.
NDT test such as dye penetrant, eddy current or
ultrasonic inspection is used to find the actual extent
of the damage.
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