Aircraft Corrosion Protection, III

Aluminum corrodes almost immediately forming an oxide layer that will protect it from further
corrosion. For example: Place an aircraft in a salty environment near the ocean and the
unprotected aluminum corrodes if not handled properly.

There are a number of ways one can protect an aircraft against corrosion: painting, waxing,
zinc-chromate priming, thin layer of pure aluminum (Alclad), anodizing and coating with a
liquid protective solution.

If done properly the aircraft can last a lifetime, or more. And its resale value will not corrode
either should you decide to properly have the materials protected against corrosion.

There are several methods to help prevent this process and each has their own typical
application area, read more below to get a basic idea.

Corrosion Treatments
If left untouched, corrosion will attack the aluminum and a possible failure of the structure
could result. Proper treatment will extend the life of the aircraft and keep its market value
high, important when you plan to resell it.

Surface layers

The most common form of corrosion protection is applying a surface layer or coating, either
in the form of paint or plating (think of chroming or Alclad). This forms an barrier of corrosion
resistant material which is easy to apply and cheaper to replace than the structure itself.

During the build phase of an aircraft, zinc-chromate primer (the yellowish green stuff) is
heavily used as protection and as a base for subsequent coats of paint.

Before any treatment with zinc-chromate or other primers the parts will need to be cleaned
of ink, glue residue and or grease. Read text below on how to do that.

Electrolytic

Anodizing is an electrolytic passivation process (much like the normal oxidation of

aluminum) and it thickens and strengthens the oxide layer and increases the wear
resistance, it also provides a better surface for paint to adhere too. The oxide layer can be
colored on request for cosmetic purposes and anodized parts are non conductive.

The process usually uses a direct current in an electrolytic solution so that a coating is build
up with pores of 10 to 150 NM which then oxidize and can be colored with a dye. The final
oxide layer thickness is around 0,5 um to 150 um and will need to be sealed.

Alodine

Alodine is a chemical treatment of aluminum to prevent corrosion, it is electrically

conductive and can be used as a primer for layers of paint. It does not add weight or
changes dimensions of the part that is being treated, where as paint does. It is easy to apply
and needs no electricity (anodizing does) to treat the parts.

Parts may not be assembled (like with anodizing) and you will need a tank that can hold the
biggest part in your kit to properly alodine. Keep temperatures above 21C (70F) for good
results. Disposal of left over chemicals may be difficult.

Preparation

Before alodining the parts will need to be cleaned

with acetone to remove all ink and or glue or sticky
stuff. Then use Scotch Brite to remove the oxide
layer and use a good dishwash detergent (dawn) to
clean any remaining grease of the parts. If this has
been done properly water will form an unbroken film, if it does not, it must be cleaned again
to remove the grease.

Then dry and immerse the parts in acid for three minutes, acid rinse and dip in the alodine
tank for another three minutes. Then rinse and let the alodined parts settle for at least 24
hours for maximum strength.

Alumetron

Alumetron is a clear polymer coating that bonds to aluminum, its a water based
chemical/mechanical process and the result is that treated parts are suitable for constant
water immersion. Application is easy through either wipe with clean cloths or spray with a
HVLP gun with fine tip. You will need to clean and degrease the parts before applying
Alumetron.

Oil coatings

The inside of wings, tail sections or the fuselage can be treated by mineral or synthetic oil
based solutions with a waxy compound, either dipped or sprayed. Capillary action makes
sure that the solution reaches every corner and section. Will need to be reapplied every
couple of years depending on the location of the aircraft.
Read more about Boeings Boeshield T-9.

Anodizing...
the Finish of Choice
What is Anodizing?
Anodizing is an electrochemical process that converts the metal surface into a decorative, durable,
corrosion-resistant, anodic oxide finish. Aluminum is ideally suited to anodizing, although other nonferrous
metals, such as magnesium and titanium, also can be anodized.
The anodic oxide structure originates from the aluminum substrate and is composed entirely of aluminum
oxide. This aluminum oxide is not applied to the surface like paint or plating, but is fully integrated with the
underlying aluminum substrate, so it cannot chip or peel. It has a highly ordered, porous structure that
allows for secondary processes such as coloring and sealing.
Anodizing is accomplished by immersing the aluminum into an acid electrolyte bath and passing an
electric current through the medium. A cathode is mounted to the inside of the anodizing tank; the
aluminum acts as an anode, so that oxygen ions are released from the electrolyte to combine with the
aluminum atoms at the surface of the part being anodized. Anodizing is, therefore, a matter of highly
controlled oxidationthe enhancement of a naturally occurring phenomenon.
Find out more about anodizing...

Anodized Aluminum Applications

An Historical Perspective

Anodizing's Benefits

Anodizing and the Environment

Anodizing Definitions and Methods

Coil Anodizing

Current Anodizing Processes

Anodic Coating Specifications

Anodic Coating Designations

Alloys Suitable for Anodizing

Ordering and Quotation Guidelines

How to Specify

Anodized finishes have made aluminum one of the most respected and widely used materials today in the
production of thousands of consumer, commercial and industrial products.
Anodized Aluminum:

Protects satellites from the harsh environment of space.

Used in one of the world's tallest buildings --- the Sears Tower in Chicago, Illinois.

Provides attractive, minimum-maintenance, highly durable exteriors, roofs, curtain walls, ceilings,
floors, escalators, lobbies and staircases in skyscrapers and commercial buildings throughout the
world.

Revolutionized the construction of computer hardware, exhibit displays for trade shows, scientific
instruments, and a constantly expanding array of home appliances, consumer products, and
building materials.

Considered environmentally safe, producing few, if any, harmful effects on land, air, or water.