Aircraft Corrosion: Acids & Alkalis C2

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Questions and Answers

Which of the following is NOT considered a common corrosive agent that affects aircraft materials?

  • Acids
  • Salts
  • Alkalis
  • Silicates (correct)

Why are aluminum and magnesium alloys particularly susceptible to corrosive attack from alkalis?

  • They react violently with any alkaline solution.
  • They become electrolytic when exposed to alkalis.
  • They are prone to corrosive attack unless the alkaline solutions contain a corrosion inhibitor. (correct)
  • They lack natural protective oxide layers.

What chemical process occurs when mercury comes in contact with aluminum in aircraft structures?

  • Oxidation
  • Amalgamation (correct)
  • Galvanization
  • Electrolysis

Why is the regular cleaning and maintenance of aircraft lavatories important in preventing corrosion?

<p>To remove corrosive substances, such as urine and fecal matter, resulting from leaky plumbing. (C)</p> Signup and view all the answers

Which aircraft area is most susceptible to corrosion due to exposure to mud, water, salt, and gravel?

<p>Wheel wells and landing gear (D)</p> Signup and view all the answers

What is the primary reason why engine mounts are prone to corrosion, especially from the inside out?

<p>The heavy current for the starter returns to the battery through the engine mount. (A)</p> Signup and view all the answers

Why are piano hinges considered prime spots for corrosion on aircraft?

<p>They involve dissimilar metal contact between a steel pin and aluminum hinge which are natural traps for dirt, salt, and moisture. (A)</p> Signup and view all the answers

Which action helps to minimize corrosion in piano hinges?

<p>Lubricating and actuating through several cycles (A)</p> Signup and view all the answers

What is the specific concern regarding aluminum welding that can lead to corrosion?

<p>The flux used in welding can cause corrosion if not completely removed. (B)</p> Signup and view all the answers

What type of corrosion primarily occurs in stainless steels or nickel-based alloys due to undesirable heat treating during welding?

<p>Weld decay (A)</p> Signup and view all the answers

Why should aircraft parked outside for extended periods be inspected for bird and mouse nests?

<p>To prevent the corrosive effects of the nests. (D)</p> Signup and view all the answers

What should be used to neutralize the area around lead acid batteries to minimize corrosion?

<p>Sodium bicarbonate (C)</p> Signup and view all the answers

What is the main reason for ensuring that bilge drains are kept clear and drain hoses are properly secured?

<p>To prevent water accumulation that can lead to ice formation and corrosion. (B)</p> Signup and view all the answers

How do certain food and beverage spills in galleys and cargo compartments contribute to corrosion?

<p>They attract and retain moisture, leading to corrosive attack. (A)</p> Signup and view all the answers

Which maintenance practice is essential for jet fuel tanks susceptible to organic growth and water accumulation?

<p>Sumping fuel tanks daily and ensuring a reliable source of clean fuel. (D)</p> Signup and view all the answers

What is the primary reason for frequent inspections of control cables, regardless of whether they are made of carbon steel or corrosion-resistant steel?

<p>To check for wear and corrosion. (A)</p> Signup and view all the answers

What is the purpose of using dielectric grease on electrical connectors and pins?

<p>To prevent moisture ingress. (A)</p> Signup and view all the answers

What is the purpose of regular cleaning and neutralization of acid deposits around aircraft batteries?

<p>To minimize corrosion from battery electrolyte. (D)</p> Signup and view all the answers

Why is it important to pay close attention to areas around rivet heads and skin lap joints during aircraft maintenance?

<p>To inspect for trapped exhaust deposits and corrosion. (C)</p> Signup and view all the answers

What potentially corrosive effect can occur in aircraft fuel tanks due to water accumulation?

<p>Organic growth and corrosion. (C)</p> Signup and view all the answers

In the context of aircraft maintenance, what does the term 'amalgamation' refer to?

<p>A chemical reaction between mercury and aluminum that causes corrosion. (D)</p> Signup and view all the answers

What is the recommended method for removing welding flux from aluminum after the welding process?

<p>Using hot water and a nonmetallic bristle brush. (D)</p> Signup and view all the answers

Why are aircraft skin seams and lap joints particularly susceptible to corrosion?

<p>The edges of the sheared aluminum skins exposes the aluminum alloy without any Alclad protection. (D)</p> Signup and view all the answers

What substances, particularly corrosive to aluminum, should be avoided or carefully controlled around aircraft?

<p>Washing soda, potash (wood ashes), and lime (cement dust). (A)</p> Signup and view all the answers

What is the most effective way to manage the risk of corrosion in aircraft bilge areas?

<p>Regular cleaning of bilge areas, maintenance protective sealant and paint finishes. (B)</p> Signup and view all the answers

What is a critical factor in preventing corrosion in control surfaces and stabilizers, especially in areas with hinges?

<p>Ensuring hinges are easily accessible for inspection. (A)</p> Signup and view all the answers

What is the role of a corrosion inhibitor when using alkaline solutions on aluminum and magnesium alloys?

<p>To prevent the alkaline solution from causing corrosive attack. (D)</p> Signup and view all the answers

What are the major atmospheric corrosive agents that affect aircraft materials?

<p>Oxygen and airborne moisture. (B)</p> Signup and view all the answers

Why must close attention be paid after an aircraft has been stripped for paint?

<p>To remove and neutralize any trace of paint stripper. (C)</p> Signup and view all the answers

What is generally used for nickel-cadmium batteries to neutralize the area around the batteries?

<p>Ammonia or boric acid (A)</p> Signup and view all the answers

What is the most likely result of corrosive buildup on aircraft control cables?

<p>Sluggish control response. (B)</p> Signup and view all the answers

Which of the following scenarios would present the HIGHEST risk of corrosion to an aircraft's aluminum components?

<p>Contact with washing soda solution (C)</p> Signup and view all the answers

Which of the following best describes how residual oil in the bilge area of an aircraft fuselage contributes to corrosion?

<p>It masks small quantities of water, setting up a hidden chemical cell. (D)</p> Signup and view all the answers

What is a key consideration when inspecting and maintaining aircraft piano hinges to prevent corrosion?

<p>Lubricating and actuating them through several cycles to ensure complete lubricant penetration. (B)</p> Signup and view all the answers

What is the most likely reason for green-colored corrosion found on electrical connectors in an aircraft?

<p>Corrosion of copper or brass components (A)</p> Signup and view all the answers

Which part of the multi piston or turbo prop engine aircraft gear bays are usually located behind?

<p>Engine nacelles and exhaust gasses (A)</p> Signup and view all the answers

What is a consequence of neglecting the sumping of fuel tanks in piston engine aircraft?

<p>Water accumulation leading to corrosion and engine problems. (A)</p> Signup and view all the answers

Why are aircraft parked outside for extended periods susceptible to corrosion from birds and mouse nests?

<p>The nests attract moisture and debris, creating a corrosive environment. (B)</p> Signup and view all the answers

Which statement best describes the relationship between alkalis and aluminum alloys in aircraft structures?

<p>Aluminum and magnesium alloys are particularly prone to corrosive attack by alkaline solutions if corrosion inhibitors are not used. (C)</p> Signup and view all the answers

What is the primary reason for concern regarding mercury in the context of aircraft maintenance and corrosion prevention?

<p>Mercury can cause amalgamation, a chemical reaction that rapidly corrodes aluminum by attacking its grain boundaries. (C)</p> Signup and view all the answers

Why are aircraft exhaust trail areas particularly susceptible to corrosion?

<p>Exhaust deposits contain corrosive substances that become trapped in gaps, seams, and crevices. (C)</p> Signup and view all the answers

How does the presence of residual oil in aircraft bilge areas contribute to corrosion?

<p>Oil traps small quantities of water and debris, creating a hidden chemical cell that promotes corrosion. (D)</p> Signup and view all the answers

Why is it crucial to neutralize paint stripper from aircraft surfaces after paint removal?

<p>To prevent any remaining traces of the stripper from causing corrosion. (C)</p> Signup and view all the answers

What is the potential consequence of corrosive buildup on aircraft control cables?

<p>Increased friction against pulleys, resulting in sluggish control response. (D)</p> Signup and view all the answers

Why is the interior of control surfaces and stabilizers prone to corrosion?

<p>They are difficult to inspect and can trap moisture and dirt, creating a corrosive environment. (D)</p> Signup and view all the answers

What is the purpose of using sodium bicarbonate around lead acid batteries in aircraft?

<p>To neutralize acid spills and minimize corrosion. (C)</p> Signup and view all the answers

Why might water accumulation in aircraft fuel tanks lead to corrosion?

<p>Water promotes the formation of organic growth and can cause corrosion to the inside of integral fuel tanks. (C)</p> Signup and view all the answers

Which of the following represents the PRIMARY agents responsible for causing corrosion in metals?

<p>Acids, alkalis, and salts (A)</p> Signup and view all the answers

Why should aircraft be thoroughly inspected after being stripped for paint?

<p>To neutralize any remaining traces of paint stripper. (A)</p> Signup and view all the answers

How does the design of control surfaces and stabilizers contribute to corrosion?

<p>Recessed designs and hinges trap moisture and dirt, promoting corrosion. (A)</p> Signup and view all the answers

Why are alloys used in airframes highly susceptible to corrosion from moderately strong acids?

<p>Acids react chemically with the metal components of the alloys. (C)</p> Signup and view all the answers

Why is flux used in aluminum welding problematic from a corrosion standpoint?

<p>It contains fluorides and chlorides, which are corrosive to aluminum. (C)</p> Signup and view all the answers

How can aircraft engine exhaust deposits lead to corrosion?

<p>By trapping corrosive substances in gaps, seams, and crevices. (B)</p> Signup and view all the answers

What is the chemical process by which mercury corrodes aluminum, and why is it particularly destructive?

<p>Amalgamation, because it attacks grain boundaries within the alloy. (B)</p> Signup and view all the answers

What consideration is most important when inspecting aircraft skin seams and lap joints for corrosion?

<p>Ensuring proper sealing to prevent moisture and electrolyte ingress. (B)</p> Signup and view all the answers

What makes engine mounts prone to corrosion, especially from the inside out?

<p>The heavy current for the starter returns to the battery through the engine mount, creating an electrical potential difference. (B)</p> Signup and view all the answers

Why are aluminum and magnesium alloys particularly susceptible to corrosive attack from alkaline solutions?

<p>Alkaline solutions readily react with the alloying elements. (C)</p> Signup and view all the answers

What is specifically corrosive to aluminum among common substances?

<p>Washing soda (B)</p> Signup and view all the answers

Frequent inspections of control cables are emphasized, whether they are made of carbon steel or stainless steel. Why?

<p>To detect wear and corrosion that could lead to failure. (B)</p> Signup and view all the answers

What is the main reason for concern about bird and mouse nests in aircraft that are parked for extended periods?

<p>The waste products from the nests can accelerate corrosion on aircraft structures. (C)</p> Signup and view all the answers

Which environmental factor significantly contributes to the corrosion of aircraft materials in marine atmospheres and industrial areas?

<p>High concentrations of salts (D)</p> Signup and view all the answers

Why is it critical to maintain clear bilge drains and properly secured drain hoses in aircraft?

<p>To prevent the accumulation of corrosive fluids that can damage the airframe. (A)</p> Signup and view all the answers

Where are multi-piston or turbo prop engine aircraft gear bays typically located?

<p>Behind the engine nacelles. (D)</p> Signup and view all the answers

Which of the following best explains why neglecting to sump fuel tanks in piston engine aircraft can lead to corrosion?

<p>It allows water and contaminants to accumulate, creating an environment conducive to corrosion. (B)</p> Signup and view all the answers

In what specific manner do salt solutions accelerate corrosion on aircraft, especially for aluminum and magnesium alloys?

<p>They are good electrolytes, promoting corrosive attack. (D)</p> Signup and view all the answers

What corrosive effect is potentially caused by water accumulation in aircraft fuel tanks and how does this impact the fuel system?

<p>Breeds organic growth and corrodes the interior of the holding tank. (C)</p> Signup and view all the answers

Among the atmospheric corrosive agents, what makes marine atmospheres and industrial areas particularly concerning for aircraft corrosion?

<p>The large concentrations of salts. (A)</p> Signup and view all the answers

Why must jet fuel tanks be checked regularly for organic growth?

<p>Organic growth can hold water and promote corrosion. (B)</p> Signup and view all the answers

Aircraft wheel wells and landing gear areas are heavily bombarded with which corrosive materials?

<p>Mud, water, salt, gravel, and flying debris. (C)</p> Signup and view all the answers

Why is proper cleaning of electrical pins or sockets crucial in aircraft maintenance?

<p>To prevent corrosion and ensure reliable electrical connections. (A)</p> Signup and view all the answers

How does the galvanic action of dissimilar metals contribute to corrosion in piano hinges?

<p>It accelerates the corrosion process because of the steel pin and aluminum hinge. (A)</p> Signup and view all the answers

Which area in an aircraft is most likely to experience corrosion due to spills of sugary drinks and foods?

<p>Cargo compartments. (A)</p> Signup and view all the answers

Which procedure is recommended to remove welding flux from aluminum after completing welding operations?

<p>Using hot water and a nonmetallic bristle brush. (D)</p> Signup and view all the answers

Why are fumes from an overheated battery electrolyte particularly dangerous?

<p>They cause rapid corrosive attacks on unprotected metal surfaces. (C)</p> Signup and view all the answers

In aircraft maintenance, what is the term 'amalgamation' associated with and what does it refer to?

<p>A chemical reaction where mercury attacks and destroys aluminum. (C)</p> Signup and view all the answers

What is the primary purpose of using dielectric grease on electrical connectors and pins in aircraft systems?

<p>To prevent moisture ingress and subsequent corrosion. (D)</p> Signup and view all the answers

What makes aircraft exhaust trail areas especially prone to corrosion?

<p>The accumulation of exhaust deposits that trap corrosive substances. (A)</p> Signup and view all the answers

How can technicians detect corrosion forming on the inside of a control cable?

<p>By visually inspecting the cable after disassembly or using radiographic methods. (A)</p> Signup and view all the answers

If alkalis come in contact with aluminum or magnesium, what should be applied unless a corrosion inhibitor is present within the alkali?

<p>Neutralizing agent. (B)</p> Signup and view all the answers

What maintenance consideration will help to reduce corrosion in aircraft engine inlets?

<p>Ensuring protective finishes are intact. (D)</p> Signup and view all the answers

What is weld decay, and on what types of alloys does it mostly occur?

<p>An intergranular corrosion that occurs in stainless steels or certain nickel-based alloys. (B)</p> Signup and view all the answers

Which of the following is a recommended practice for preventing corrosion in piano hinges during aircraft maintenance?

<p>Using water-displacing lubricants and actuating the hinge through several cycles. (B)</p> Signup and view all the answers

Which areas of the airplane are the most important to maintain and clean in order to prevent corrosion and maintain a safe environment?

<p>Bilge areas of galleys and lavatories. (B)</p> Signup and view all the answers

Why are aluminum and magnesium alloys particularly susceptible to corrosion from alkaline solutions?

<p>Alkalis can dissolve the protective oxide layer on these alloys, accelerating corrosion. (B)</p> Signup and view all the answers

What is the chemical process called when mercury corrodes aluminum in aircraft structures?

<p>Amalgamation (B)</p> Signup and view all the answers

Which action is most important after an aircraft has been stripped of paint to prevent corrosion?

<p>Neutralizing any remaining traces of paint stripper. (C)</p> Signup and view all the answers

Why is the regular sumping of fuel tanks especially important for aircraft using leaded aviation fuel?

<p>To remove water and contaminants that promote corrosion. (D)</p> Signup and view all the answers

Why do engine mounts experience a higher rate of corrosion compared to other parts of the aircraft?

<p>They serve as the return path for heavy current from the starter, creating an electrical potential difference. (D)</p> Signup and view all the answers

In what way do marine atmospheres and industrial areas pose a higher risk of corrosion to aircraft materials?

<p>Elevated concentrations of salt and pollutants that precipitate and attract moisture. (C)</p> Signup and view all the answers

Why are aircraft skin seams and lap joints prone to corrosion?

<p>Water and cleaning solvents can become trapped between the skins. (C)</p> Signup and view all the answers

How does corrosion on aircraft control cables typically affect their operation?

<p>It leads to a sluggish control response due to increased friction. (B)</p> Signup and view all the answers

In the context of aircraft corrosion prevention, what is the PRIMARY reason for concern about bird and mouse nests in parked aircraft?

<p>Animal waste products are corrosive and nests trap moisture. (A)</p> Signup and view all the answers

What is the most likely reason for finding green-colored corrosion on electrical connectors in an aircraft?

<p>Corrosion of copper or brass components. (B)</p> Signup and view all the answers

Flashcards

Corrosive agents

Substances causing metal corrosion, including acids, alkalis, and salts. Atmosphere and water also contribute.

Effect of Acids

Severely corrode airframe alloys; sulfuric, halogen, nitrous oxide, and organic acids are the most destructive.

Nests in aircraft

Can cause corrosion in parked aircraft; regular inspections and protective coverings are needed

Leaky lavatory systems

Can cause rapid corrosion; requires regular cleaning around affected areas.

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Alkalis

Less corrosive than acids, but aluminum and magnesium alloys are very prone to attack unless inhibitors are present

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Corrosive Substances to Aluminum

Including washing soda, potash, and lime, are particularly corrosive to aluminum.

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Ammonia's Effect

An exception, as aluminum alloys are highly resistant to it.

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Effect of Salts

Most are good electrolytes, promoting corrosion; aluminum, magnesium alloys, and other steels are extremely vulnerable.

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Atmospheric Corrosive Agents

Oxygen and airborne moisture are major agents, along with corrosive gases, industrial contaminants and marine salt spray

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Mercury's Effect

Attacks aluminum through a chemical reaction, destroying the material rapidly.

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Paint Stripper

Very corrosive if not properly removed and neutralized.

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Engine Exhaust Deposits

Very corrosive, especially in areas where gaps, seams, hinges, and fairings are present.

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Neutralizing Battery Corrosion

Sodium bicarbonate neutralizes around lead acid batteries; ammonia or boric acid for nickel-cadmium batteries.

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Bilge Areas

Located at fuselage bottom, collecting hydraulic fluids, water, and debris; supports hidden chemical reactions.

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Aircraft Drain Holes

Require clearing to prevent corrosion from accumulated fluids and debris.

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Seaplane Structures

Requires maintained protection to prevent corrosion in these areas.

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Lavatories, Galleys Corrosion

Can cause corrosion due to trapped moisture and contaminants; regular cleaning prevents this.

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Wheel Well and Landing Gear

Receive punishment from mud, water, salt, gravel, and debris; require frequent inspection.

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Landing Gear Corrosion Areas

Exposed rigid tubing, crevices, axles, and hardware are most susceptible.

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Engine Inlets

Constantly abraded by airborne dirt, dust, and gravel, leading to a loss of protective finish and corrosion.

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Piano Hinges

Contact leads corrode; check hinge lubricant often!

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Control Surfaces Interior

Hard to inspect; trap moisture. Hinges attract corrosion.

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Jet Fuel Tanks

Highly susceptible to organic growth and water retention, causing corrosion.

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Carbon Steel Cables

Prone to corrosion if unprotected; water gets between strands.

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Aluminum Welding Flux

If incompletely removed after welding, can cause corrosion.

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Weld Decay

Occurs in stainless steels or nickel-based alloys due to heat treating during welding, damaging grain boundaries.

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Engine Mounts

Electrical potential difference causes corrosion; corrode from the inside out.

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Skin Seams and Lap Joints

Aluminum skins' sheared edges need frequent inspection and cleaning to prevent corrosion.

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Electrical Components Corrosion

Contact with pollutants causes corrosion; copper or brass corrosion leaves green oxide.

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Acid strength and corrosion

Moderately strong; it severely corrodes most alloys used in airframes.

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Preventing animal nest corrosion

Inspecting, using engine plugs, probe covers, and other protective coverings prevent animal nest corrosion.

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Atmospheric corrosion

Are often oxygen and airborne moisture but may also contain corrosive gases and contaminants.

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Swaged Cable Corrosion

Areas where control cables are secured are prone to corrosion.

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Minimizing battery electrolyte corrosion

Regular cleaning and neutralization of acid deposits can minimize corrosion.

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Aircraft Control Cables

The cables used in aircraft control systems are made of either carbon steel, or corrosion-resistant steel (galvanized or stainless steel).

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Study Notes

  • Substances causing metal corrosion are corrosive agents.
  • Acids, alkalis, and salts are the most common corrosive agents.
  • The atmosphere and water also act as corrosive agents.

Acids

  • Moderately strong acids severely corrode most airframe alloys.
  • Sulfuric acid (battery acid), halogen acids (hydrochloric, hydrofluoric, hydrobromic), nitrous oxide compounds, and organic acids found in human and animal waste are the most destructive acids.
  • Birds and mice nesting in aircraft can have a corrosive effect.
  • Aircraft parked outside or in open enclosures for extended periods are at risk of animal nesting.
  • Regular inspections and protective coverings for engine plugs and probes are needed.

Alkalis

  • Alkalis are generally less corrosive than acids.
  • Aluminum and magnesium alloys are highly prone to corrosive attack by alkaline solutions unless a corrosion inhibitor is present.
  • Washing soda, potash (wood ashes), and lime (cement dust) are particularly corrosive to aluminum.
  • Ammonia is an exception; aluminum alloys are highly resistant to it.
  • Leaky lavatory systems also cause a rapid rate of corrosion which means the area around the lavatory should be cleaned regularly.

Salts

  • Most salt solutions are good electrolytes and promote corrosive attack.
  • Stainless-steel alloys are resistant to salt solutions.
  • Aluminum, magnesium alloys, and other steels are extremely vulnerable to salt solutions.
  • Exposure of airframe materials to salts is undesirable.

Atmosphere

  • Oxygen and airborne moisture are major atmospheric corrosive agents.
  • The atmosphere contains other corrosive gases, industrial contaminants, and marine salt spray.
  • Marine and industrial atmospheres have high salt concentrations.
  • Chemicals precipitate, collect moisture, and cause corrosion. Acid rain also corrodes aircraft metals.

Mercury

  • Mercury isn't commonly used around aircraft but may be in cargo.
  • It attacks aluminum via amalgamation and destroys the material quickly.

Paint Stripper

  • Paint stripper is highly corrosive if not correctly removed and neutralized after use.
  • Close attention including removing and neutralizing any trace of paint stripper should be given after stripping paint on an aircraft.

Corrosion Prone Areas

Exhaust Trail Areas

  • Exhaust deposits from jet and reciprocating engines are very corrosive because of gaps, seams, hinges, and fairings which are located downstream from the exhaust pipes or nozzles.
  • Deposits may be trapped and inaccessible by normal cleaning and therefore rivet heads and skin lap joints require special attention.

Battery Compartment

  • Fumes from overheated electrolyte are difficult to contain, which causes rapid corrosion on unprotected metal surfaces.
  • Regular cleaning and acid deposit neutralization minimizes corrosion.
  • Sodium bicarbonate neutralizes lead acid batteries, whereas ammonia or boric acid is used for nickel-cadmium batteries.

Bilge Areas and Drains

  • The bottom of the fuselage is a natural collection point for waste hydraulic fluids, water, dirt, and debris.
  • Residual oil masks water, creating a hidden chemical cell.
  • Blocked bilge drains and unsecured drain hoses cause problems by freezing the NWS control cable.
  • Aircraft drain holes should be cleared and drained to prevent clogging and corrosion.
  • Instead of chemical treatments for the bilge water, current float manufacturers recommend the diligent maintenance of the internal coatings applied to the float’s interior during manufacture.

Lavatories, Buffets and Galleys

  • Spilled food and waste behind lavatories, sinks, and ranges attract moisture and cause corrosion.
  • Pay special attention to bilge areas under galleys and lavatories and maintain the protective sealant and paint finishes.
  • Wine, sugary drinks, food, fruit, and vegetables in cargo compartments are very corrosive.
  • Urine and fecal matter from leaky plumbing also cause corrosion, so leaks need to be contained during repairs.

Wheel Well and Landing Gear

  • Wheel wells and landing gear receive punishment from mud, water, salt, gravel, and flying debris.
  • Gear bays should be kept clean from grease, oil, and exhaust.
  • On multi piston or turbo prop engine aircraft the gear bays are usually behind the engine nacelles and exhaust gasses are present
  • Exposed rigid tubing (especially at B-nuts and ferrules), clamps, tubing identification tapes, position indicator switches, electrical equipment, stiffener crevices, ribs, lower skin surfaces, struts, oleos, arms, links, and attaching hardware are all susceptible to corrosion.

Engine Inlets

  • Engine inlet areas are constantly abraded by airborne dirt, dust, gravel from runways, and rain, leading to removal of the protective finish.
  • Erosion also impacts the leading edges of wings, stabilizers, propellers, and rotor leading edges on helicopters.
  • Remember when the protective coating such as paint is lost on the surface of aircraft metals those metals become susceptible to many forms of corrosion.

Piano Hinges

  • Piano hinges are prime corrosion spots due to dissimilar metal contact between the steel pin and the aluminum hinge.
  • Hinges trap dirt, salt, and moisture.
  • Inspection must include lubrication and actuation to ensure complete lubricant penetration with water-displacing lubricants.

Control Surfaces

  • Control surfaces and stabilizers are hard to inspect and trap moisture.
  • Recessed control surfaces in wings and stabilizers make hinges hard to access for inspection.
  • Hinges trap moisture and dirt, which causes corrosion.

Fuel Tanks

  • Jet fuel tanks are highly susceptible to organic growth that holds water, which causes corrosion. Integral fuel tanks are particularly at risk.
  • Sealants in tanks are impervious to fuel but not always to water.
  • Daily fuel tank sumping is essential.
  • Improper sumping of fuel can set up an area for corrosion, but can also lead to water build-up that turns to ice at altitude and creates havoc to the fuel quantity indication system.
  • Fuel tanks in piston engine aircraft that hold leaded aviation fuel also need to be sumped daily due to water in the tanks caused by condensation or contaminated fuel, bad fuel cap seal, or pilots leaving the gas cap off in the rain.

Control Cables

  • Aircraft control system cables are made of carbon steel or corrosion-resistant steel such as galvanized or stainless steel.
  • Unprotected carbon steel cables corrode when water gets between the strands.
  • Corrosion that forms on the inside the cable will be hard to detect.
  • Areas where cables are swaged are also corrosion prone.
  • Corrosive buildup increases friction against pulleys, causing sluggish control response.
  • All cables must be inspected frequently for corrosion and wear.

Welded Areas

  • Aluminum welding requires the use of flux to exclude oxygen.
  • Welding flux contains fluorides and chlorides and bisulfides which are extremely corrosive to aluminium.
  • If not fully removed post-welding, corrosion can occur.
  • Welding flux dissolves with hot water and a nonmetallic bristle brush.
  • Weld decay is intergranular corrosion adjacent to welds caused by heat treating of metals. Attack on grain boundaries can cause cracking and grain loss.
  • Weld decay occurs mostly in stainless steels or nickel-based alloys.

Engine Mounts

  • Engine mounts are corrosion prone because the starter's heavy current returns to the battery through the engine mount.
  • This sets up an electrical potential difference, causing corrosion, and engine mounts corrode from the inside out.
  • SAE grade 4130 steel, also known as chrome-moly (chromoly), is used in most small aircraft engine mounts.
  • Surface corrosion should be treated, welded areas inspected carefully and firewalls inspected for corrosion.

Skin Seams and Lap Joints

  • Sheared aluminum skin edges expose aluminum alloy without Alclad protection.
  • Corrosion will propagate from sheared edges or drilled holes.
  • Water and cleaning solvents can get trapped between skins.
  • These edges are sealed with PRC on commercial aircraft but not on general aviation aircraft and therefore the edges are to be inspected frequently and kept clean.

Electrical Connectors, Wire, Circuit Breakers and Switches

  • Electrical items are prone to corrosion in contact with moisture or high temperature, humidity, atmospheric pollutants, de-ice fluid, or hydraulic fluid.
  • Internal corrosion of switches, connectors, and circuit breakers causes arcing leading to system faults/failures.
  • Copper, lead, and tin wiring are targets for corrosion.
  • Copper or brass corrosion leaves a green oxide.
  • Electrical pins/sockets need regular cleaning with contact cleaner. Dielectric grease prevents moisture ingress.
  • Most commercial aircraft pins and sockets are made out of Gold.

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