Corrosion Suppression of

Aircraft Alloys via Selected

Corrosion Preventative
Compounds (CPCs)
Sponsored by
AFRL/ML 6.3 Program Office

Ryan Leard, James Dante, UDRI

Dr. Deborah T. Peeler, AFRL/MLOB
 Outline

• Background
• Objective
• Approach
• Mass loss results
• Visual observation results
• Metallographic Inspections
• Conclusions
• Ongoing efforts

2
 CPCs are used to suppress
corrosion in specific areas.

To reduce corrosion of the

aircraft, thereby decrease
maintenance time and costs.

CPCs may be used

• in corrosion prone areas. Ex.
wheel wells, sloping longeron,
“bath tub joint”, etc.
• when coating systems in place
have been compromised.

3
 CPC products were selected
for performance evaluation.

There are several CPCs available, Nine different CPCs are

under evaluation:
with very different
characteristics. 1. Cor-Ban 22
• Water displacing 2. Cor-Ban 35
soft film, hard film, thin film 3. Corrosion X Aviation

• Non-water displacing 4. LPS- Procyon

soft film, hard film, thin film

5. LPS-2
6. LPS-3
Laboratory test method was
developed to evaluate their 7. VCI-386
corrosion suppression 8. VCI-396
effectiveness.
9. Dinitrol AV-15

4
 Objectives of this CPC evaluation.

Accelerated laboratory test method to evaluate CPC

performance
• On different common structural aircraft alloys
1. AA2024-T3
2. AA7075-T6
3. HT4130
• In three different aircraft structures
1. Boldly exposed
2. Single metal lap joints
3. Galvanic couple lap joints
5
 Sample geometries were chosen to
mimic structural components.

Hi-lok fasteners
Specimen Geometries: Upper panel

• Boldly exposed panels 1” 1Ó

0.050Ó

• Single Metal Lap Joints

Insid e panel

• Galvanic Couple Lap Joints Lower panel

Al Hi-lok collars
(3” by 3 ”by 0.050 ”)

HL77-6

1. 8 different specimen build-ups:

Hi-lok fasteners
Upper panel

Boldy
AA2024-T3 AA7075-T6 HT 4130
Exposed 0.050Ó

Single Metal 1Ó 1Ó
AA2024-T3 AA7075-T6 HT 4130
Laps
Galvanic AA2024-T3 AA7075-T6
Insid e panels
Couple Laps & HT 4130 & HT 4130 Lower panel (3” by 3 ”by 0.050 ”)

Al Hi-lok collars
HL77-6

6
 Modified GM9540 exposure
completed with Q-Fog chambers.
Salt mist is applied by using a portable hand sprayer. Panels are
completely wetted with the following electrolyte solution:
0.9% NaCl, 0.1% CaCl2, & 0.25 NaHCO3 pH between 6.0 and 8.0.

GM9540Single cycle schedule:

10 minutes Salt mist
90 minutes Ambient (25 °C, 30 - 50% RH)
10 minutes Salt mist
90 minutes Ambient (25 °C, 30 - 50% RH)
10 minutes Salt mist
90 minutes Ambient (25 °C, 30 - 50% RH)
10 minutes Salt mist
170 minutes Ambient (25 °C, 30 - 50% RH)
8 hours Humidity (95 - 100% RH)
8 hours Dry Off (60 °C, <30% RH)
Repeat
7
 Visual and analytical evaluation of
corrosion suppression.

Exposure: GM9540
Specimens are pre-corroded for 1 week.
CPCs spray applied to front surface of specimens,
including lap joint mouth. CPCs allowed to cure for
3 days at room temperature prior to accelerated
corrosion environment exposure.
Evaluations at 3, 6, and 9 week periods.
• Visual comparison of corrosion damage
• Mass loss measurements
• Metallographic cross-section evaluations
8
 Mass loss measurements taken in
accordance with ASTM G1.

• Aluminum panels cleaned in 50% NO3 for 3 minutes.

• Rinsed with DIW and then alcohol.
• Light scraping used to remove stubborn CPC product.
• Weighed. 19.15
2024 Mass Loss
A3K57 388

A3K55 391

• Repeated. 19.1

19.05
Mass (grams)

19

5minute value
A3K55 = 18.9069
A3K57 = 18.9123
18.95
A3K57 Trend A3K57 Trend 2
y = -0.0006x + 18.912 y = -0.0006x + 18.908
2
R = 0.9759 R2 = 0.9999
18.9
A3K55 Trend
y = -0.0008x + 18.908
2
R = 0.9882
18.85
0 10 20 30 40 50 60 70
Time in 50% Nitric Bath (minutes)

9
 Boldly exposed mass loss results
after 9 weeks of exposure.
 1000mg 
MassLoss  Initialweight  Finalweight
118.2cm 2 
Boldly Exposed - 9 weeks

5
4.5 AA2024-T3
Mass Loss (mg/cm2)

4 AA7075-T6
3.5
3
2.5
2
1.5
1
0.5
0

VCI 368

VCI 396
Corrosion
Corban 22

Corban 35

Procyon

none
LPS 2

LPS 3
Dinitrol
AV15

LPS
X

10
Single metal lap joint mass loss
rates after 3 weeks of exposure.

11
Single metal lap joint mass loss
rates after 6 weeks of exposure.

12
 Single metal lap joint mass loss
rates after 9 weeks of exposure.
9 wk Single Metal Laps

6
AA2024-T3
AA7075-T6

4
Mass Loss (mg/cm )
2

0
VCI 368 LPS 2 LPS 3 Dinitrol AV15 Corrosion X Corban 22 Corban 35 LPS Procyon VCI 396 none
Corrosion Preventative Compounds (CPC)

 1000mg 
MassLoss  Initialweight  Finalweight
118.2cm 2 
13
 Aluminum panel from galvanic
couple laps mass loss. 3 weeks.

14
 Aluminum panel from galvanic
couple laps mass loss. 6 weeks.

15
 Aluminum panel from galvanic
couple laps mass loss. 9 weeks.

16
 Steel panel mass loss from GC Laps
after 3 weeks of exposure.
HT 4130 Mass Loss after 3 weeks exposure

7
AA2024-T3 GC Laps

6 AA7075-T6 GC Laps

5
Mass Loss (mg/cm )
2

0
VCI 368 LPS 2 LPS 3 Dinitrol Corrosion X Corban 22 Corban 35 LPS VCI 396 No CPC
AV15 Procyon
-1
Corrosion Preventative Compounds

17
 Steel panel mass loss from GC Laps
after 6 weeks of exposure.
6 Week Exposure Mass Loss for HT 4130 Panels

40

AA2024-T3 GC Laps
35
AA7075-T6 GC Laps

30
Mass Loss (mg/cm )
2

25

20

15

10

0
VCI 368 LPS 2 LPS 3 Dinitrol Corrosion X CorBan 22 LPS CorBan 35 VCI 396 No CPC
AV15 Aviation Procyon
Corrosion Preventative Compounds

18
 Steel panel mass loss from GC Laps
after 9 weeks of exposure.
HT 4130 Mass Loss after 9 week exposure

60

AA2024-T3 GC Laps

50 AA7075-T6 GC Laps

40
Mass Loss (mg/cm )
2

30

20

10

0
VCI 368 LPS 2 LPS 3 Dinitrol Corrosion X CorBan 22 CorBan 35 LPS VCI 396 No CPC
AV15 Aviation Procyon
Corrosion Prevenative Compounds

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Percent protection factors for boldly
exposed and single metal laps.

 MLnone 
Percent Protection    1100%
 MLCPC 
20
 Percent protection factors for AA
and steel panels from galvanic laps.

 MLnone 
Percent Protection    1100%
 MLCPC 

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 Relative effectiveness rankings
based on mass loss results.

• Mass loss rankings from each specimen geometry were

compiled across all exposure times to develop overall relative
effectiveness rankings. The top five performers are presented.

22
 Visual observations do not correlate
to component damage.
Boldly Exposed Single Metal Laps Galvanic Couple Laps
3 weeks 3 weeks 3 weeks
AA2024-T3 AA7075-T6 AA2024-T3 AA7075-T6 HT-4130 AA2024-T3 AA7075-T6
1 VCI 396 VCI 396 1 Corrosion X LPS 2 Corrosion X 1 Corrosion X Corrosion X
2 none CorBan 35 2 LPS 2 Corrosion X CorBan 35 2 LPS 2 LPS 2
3 CorBan 35 Procyon 3 AV15 AV15 LPS 3 3 VCI 368 AV 15
4 LPS 2 none 4 Procyon LPS 3 VCI 396 4 CorBan 22 LPS 3
5 Procyon AV15 5 CorBan 35 VCI 396 LPS 2 5 VCI 396 VCI 368

6 weeks 6 weeks 6 weeks

AA2024-T3 AA7075-T6 AA2024-T3 AA7075-T6 HT-4130 AA2024-T3 AA7075-T6
1 Corrosion X Corrosion X 1 Corrosion X Corrosion X VCI 368 1 Procyon Corrosion X
2 LPS 2 LPS 2 2 LPS 2 LPS 2 LPS 2 2 LPS 2 AV15
3 LPS 3 none 3 CorBan 22 CorBan 35 Corrosion X 3 LPS 3 CorBan 35
4 Corban 35 AV15 4 AV15 CorBan 22 CorBan 22 4 Corrosion X LPS 2
5 none Procyon 5 CorBan 35 Procyon VCI 396 5 AV15 none

9 weeks 9 weeks 9 weeks

AA2024-T3 AA7075-T6 AA2024-T3 AA7075-T6 HT-4130 AA2024-T3 AA7075-T6
1 LPS 3 Corrosion X 1 Corrosion X Corrosion X Procyon 1 CorBan 35 Procyon
2 VCI 368 VCI 396 2 LPS 2 LPS 2 CorBan 22 2 Procyon VCI 396
3 Corrosion X CorBan 35 3 AV15 LPS 3 CorBan 35 3 LPS 2 Corrosion X
4 LPS 2 LPS 2 4 CorBan 35 AV15 none 4 LPS 3 CorBan 35
5 CorBan 35 none 5 LPS 3 Procyon Corrosion X 5 CorBan 22 LPS 3

There was no correlation observed between visual

observations and mass loss results. Visual observations
are not a credible metric to determine structural integrity.
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 Metallographic evaluation results
are nearly complete

• A representative panel from

each exposure was prepared
in cross section for
metallographic inspection.
• Preliminary results are very AA2024-T3 3wk SML AA7075-T6 9wk
important. Some CPC that with CorBan 35. GCL with VCI-368.
may have performed well in
mass loss, have allowed
significant corrosion to occur
in lap joint geometries.

AA7075-T6 3wk AA2024-T3 9wk

Bold with Procyon. GCL with LPS 2.

24
Metallographic inspections provide
key corrosion information.

25
Cross-sections provide a better view
of corrosion than mass loss.

• Maintainers are required to

remove corrosion by grinding
out till no corrosion is
observed.
• Therefore the most important
metric will be maximum
corrosion attack (depth).
• The mechanism of corrosion
(pitting vs exfoliation) does
play an important role in the
survivability of a component.

26
 Metallographic cross-section
results for 6wk AA7075 bolds.
6wk B 7075

350 0.090
Maximum Attack
Median Attack 0.080
300
Attack Frequency
0.070

Attack Frequency (#sites/mm)

250
Attack Depth (microns)

0.060

200 0.050

150 0.040

0.030
100
0.020

50
0.010

0 0.000
VCI 368 LPS 2 LPS 3 Dinitrol Corrosion X CorBan 22 LPS CorBan 35 VCI 396 No CPC
AV15 Aviation Procyon
Corrosion Preventative Compounds

27
 Metallographic cross-section
results for 6wk AA2024 GC Laps.
6wk GC 2024

500 3.000
Maximum Attack
Median Attack
450
Attack Frequency
2.500
400

Attack Frequency (#sites/mm)

350
Attack Depth (microns)

2.000
300

250 1.500

200
1.000
150

100
0.500
50

0 0.000
VCI 368 LPS 2 LPS 3 Dinitrol Corrosion X CorBan 22 LPS CorBan 35 VCI 396 No CPC
AV15 Aviation Procyon

Corrosion Preventative Compounds

28
 Conclusions

• Mass loss provides a good measure of overall material

protection for individual specimen geometries,
however, other factors should be considered.
• CPC effectiveness determination requires
consideration of the cross-section evaluations.
• CPC performance and reapplication intervals are
dependant on alloy composition, the structural
assembly to be protected, and the complicating
realities of the surrounding operational environment.

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 Ongoing Effort

• Metallographic data will be finalized and correlated

with mass loss data with structural impact.
• Complimentary study is looking at crack growth rate
suppression by CPCs.
• Various outdoor location exposures of selected
specimens will be used to quantify an acceleration
factor for laboratory testing.
• CPC effectiveness during fatigue testing (initiation and
crack growth rate)

30