CLEANING AND CORROSION

INTRODUCTION
Corrosion is the inevitable result when metals are exposed to water and air. Since all aircraft contain some metal,
they require constant inspection and cleaning to minimize the destructive effects of corrosion. Dirt and grease are
visually unappealing, and can hide corrosion and structural damage. Furthermore, dirt can trap moisture and cor-
rosive materials next to aircraft structures, hastening the formation of corrosion. Therefore, you must be aware of
proper cleaning procedures that remove built up contamination without damaging the materials used in structural
components. In addition, you must learn appropriate methods of corrosion control to minimize corrosion's effects
once it has become established.
While a clean aircraft is more visually appealing than a dirty one, appearance is a secondary consideration in aircraft
cleaning. Appendix D of FAR Part 43 requires that the airframe and engine be cleaned before performing an annual or 100
hour inspection. In addition, common sense and good maintenance practice require that an aircraft be kept clean. Dirt
can cover up cracked or damaged components as well as trap moisture and solvents that lead to corrosion. If allowed to
accumulate over time, dirt and debris can build to a considerable weight and decrease the useful load of the aircraft.
Therefore, the cleaning of the aircraft exterior and interior should not be taken lightly.

The materials and procedures presented in this section are intended as guidelines only. You should always follow the
manufacturer's recommendations for cleaners, solvents, and cleaning procedures.

EXTERIOR CLEANING
The first and most important step in corrosion control is to keep the exterior of an aircraft thoroughly clean. However, before
you start washing an aircraft there are certain areas and components that must be protected from cleaners and water sprays.
For example, pitot tubes and static openings should always be plugged or taped prior to cleaning an aircraft to prevent
water ingestion. Furthermore, wheel and brake assemblies should be covered to keep out cleaning agents. Although not
readily apparent, it is extremely important to use the cleaning compounds and other chemicals that are recommended by the
aircraft manufacturer, or are MIL SPEC approved for the particular application. The use of nonapproved or ordinary
commercial compounds can result in a condition known as hydrogen embrittlement. Hydrogen embrit-tlement results when
a chemical reaction produces hydrogen gas that is absorbed into a metal. This process subsequently reduces a metal's
ductility and allows the formation of cracks and stress corrosion.

When washing an aircraft the aircraft should be parked on a wash rack or in an area where it can be
hosed down. Avoid washing an aircraft in the sun to help prevent the surface from drying before the cleaner has time
to penetrate the film and dirt. For the main part of the aircraft exterior, use a 1:5 or a 1:3 mixture of water and an
emulsion-type cleaner that meets MIL-C-15769 specifications. Brush or spray the mixture onto the surface and allow it
to stand for a few minutes, then rinse it off with a high-pressure stream of warm water.

The engine cowling and wheel well area usually have grease or oil deposits that require special treatment. Typically,
these areas must be soaked with a 1:2 mixture of emulsion cleaner and water. After allowing the cleaner to remain on
the surface for a few minutes, scrub the heavily soiled areas with a soft bristle brush to completely loosen the dirt, and
rinse it with a high-pressure stream of warm water. [Figure 12-1]

Figure 12-1. Wheel wells accumulate deposits of dirt, oil, and hydraulic fluid. An emulsifying cleaner should be sprayed into the
wheel well and allowed to soak, then washed off with water.
Cleaning and Corrosion 12-3
Stubborn exhaust stains may require a 1:2 mixture of EXTERIOR FINISH MAINTENANCE
cleaner with Varsol or kerosene. Mix these ingredients
into a creamy emulsion and apply it to the surface. Let A clean, polished surface denies corrosion a place
it stand for a few minutes, then work all of the to start. Therefore, aircraft should be kept clean and
loosened residue with a bristle brush and hose it off waxed. All drain openings must be kept open, and
with a high-pressure stream of warm water. This deposits which have formed from engine exhausts
treatment may be repeated if the first application does must be removed before they build up excessively.
not remove all of the stain. Avoid damage to aircraft by not using harmful
cleaning, polishing, brightening or paint-removing
materials. Use only those compounds which con-
The type of materials to be used in cleaning form to existing government or established industry
depends on the nature of the elements that need to be specifications, or products that have been specifi-
removed. For example, to remove oil, grease, or soft cally recommended by the aircraft manufacturer as
preservative compounds, dry-cleaning solvent, or being satisfactory for the intended application.
naphtha, is often used. The two most common types of Observe the product manufacturer's recommenda-
naphtha are aliphatic naphtha and aromatic naphtha. tions concerning use of their agent.
Aliphatic naphtha is a hydrocarbon solvent that
dissolves oil and grease but does not harm rubber or
acrylic components. Aromatic naphtha, on the other
hand, attacks rubber and acrylic compounds. Because NONMETAL CLEANING
it is safe on most materials, aliphatic naphtha is Nonmetalic aircraft components sometimes
frequently used to wipe down cleaned surfaces before require different cleaning techniques than metal
painting. parts. For example, the slightest amount of dust on
a plastic or plexiglass surface can scratch the finish
Chemical cleaners must be used with great care in if rubbed with a dry cloth. Furthermore, the use of
dry cloths also builds up static charges on the win-
cleaning assembled aircraft. The danger of entrapping a
dow that attracts more dust. Therefore, before
potentially corrosive solvent in faying surfaces and
washing a plastic window, rinse the area with
crevices counteracts any advantages in their speed and
water first. Once clean, dry the window with a soft
effectiveness. For example, caustic cleaners can cause cloth to prevent streaking.
corrosion on aluminum or magnesium alloys and,
therefore, should not be used. Magnesium engine parts
should be washed with a commercial solvent and Oil and hydraulic fluid attack and rapidly destroy
decarbonized, and then scraped or grit blasted. Before the rubber in aircraft tires. Therefore, whenever
they are painted, magnesium engine parts should be these fluids are spilled on a tire, they should be
wiped down with a dichromate solution to improve immediately wiped off with a dry towel. The tire
paint adhesion. When cleaning aluminum, you should should then be washed with soap and water.
always use cleaners which are relatively neutral and Because most cleaning solvents are petroleum-
easy to remove. If you must use an abrasive to remove based, soap and water are the only approved solu-
corrosion products from aluminum structure, use alu- tion for cleaning tires.
minum wool or aluminum oxide sandpaper.
Carborundum paper, crocus cloth, and steel wool must Rubber deice boots have a conductive coating to
be avoided, since they can lead to the formation of help dissipate static charges. Furthermore, some
dissimilar corrosion in aluminum. composite structures such as radomes are painted
with special materials that are transparent to radio
When using high-pressure water spray you must signals. These areas should be cleaned gently and
exercise caution. This is especially true around the never subjected to abrasives or stiff brushes. If you
engine components. For example, if high-pressure have a question as to what type of cleaning solution
water is used to degrease an engine, you must avoid to use, consult the manufacturer's specifications.
spraying electrical components such as magnetos and
wiring harnesses. Furthermore, high-pressure water
spray can rinse the lubricant from bearings and grease POWERPLANT CLEANING
fittings. Therefore, after washing wheel wells, flap
tracks, or hinges, you should lubricate them to force Accumulated dirt on powerplants can cover defects
out any water and prevent corrosion. and lead to overheating. Therefore, aircraft engines
should be cleaned on a regular basis. However,
72-4 Cleaning and Corrosion
when doing this all electrical components in the to the engine and allow it to set for several minutes.
engine compartment must be protected from solvent Heavy accumulations of dirt and grease can be
and soap. This includes wrapping the magnetos so scrubbed with a bristle brush to loosen them. The
no water can get in the vents. If the powerplant is engine is then rinsed and allowed to dry. If volatile
located over a landing gear, the gear's brake and tire solvent was used, be sure it has dried before starting
assemblies should be covered in plastic. If you use the engine to minimize the risk of fire. Lubricate all
a high-pressure water spray, avoid spraying the controls and rod ends in the engine compartment,
starter, alternator, and air intakes with solvent or and remove protective covers that were installed on
water rinse. electrical components.

Prior to washing an engine, inspect it for excessive

General cleaning sequence

1, cool down aircraft

2, protect the areas that can not be touch by water

Pitot tube, Static head, TAT, SAT, OAT

Window, radome

tire

deicing boot

electrical connection

3, wash aircraft

4, lubrication
TYPES OF CORROSION
CORROSION---corrosion prone area There are two general classifications of corrosion,
chemical and electrochemical; however, both types
Corrosion and its control are of primary importance to all involve two simultaneous changes. The metal that is
aircraft operators. Corrosion weakens primary structural attacked or oxidized suffers an anodic change, and
members, which must then be replaced or reinforced in the corrosive agent is reduced and suffers a cathodic
order to sustain flight loads. Such replacements or change.
reinforcements are costly, time-consuming, and result in
unscheduled delays.
Most metals exist in nature as chemical compounds CHEMICAL CORROSION
such as oxides or chlorides. For example, aluminum is
never found in nature in its pure state, but must be Pure chemical corrosion results from direct exposure
refined from an ore such as alumina (A12O3). However, of a bare surface to caustic liquid or gaseous agents.
when pure aluminum is exposed to the elements, it The most common agents causing direct chemical
combines with oxygen and eventually changes back to corrosion include:
alumina. Corrosion then, is simply a process wherein
metals return to a natural state. 1. Spilled battery acid or fumes from batteries.
2. Residual flux deposits resulting from inade-
quately cleaned, welded, brazed, or soldered
joints.
3. Entrapped caustic cleaning solutions.
Corrosion is a natural phenomenon which attacks metal
by chemical or electrochemical action and converts it
into a metallic compound, such as an oxide, hydroxide, ELECTROCHEMICAL CORROSION
or sulfate. Substances that cause corrosion are called Electrochemical corrosion is similar to the electrolytic
corrosive agents. Water or water vapor containing salt reaction that takes place in a dry cell battery. To
combine with oxygen in the atmosphere to produce the understand how this happens, recall the structure of
most prominent corrosive agents. Additional corrosive the atom from Chapter 2. When the number of
agents include acids, alkalis, and salts.
electrons matches the number of protons in an atom,
the atom is said to be electrically balanced. However,
if there are more or fewer electrons than protons, the
The appearance of corrosion varies with various metals. atom is said to be charged and is called an ion. If there
For example, on aluminum alloys and magnesium it are more electrons than protons, it is a negative ion,
appears as surface pitting and etching, often combined but if there are more protons than electrons, it is a
with a grey or white powdery deposit. However, on positive ion. An ion is unstable, always seeking to
copper and copper alloys corrosion forms a greenish film lose or gain electrons so it can change back into a
and on steel a reddish rust. When corrosion deposits are balanced, or neutral, atom.
removed, the metal's surface may appear etched and
pitted, depending upon the length and severity of attack. Metals are arranged to show the relative ease with
If deep enough, these pits may become sites for crack which they ionize in what is called the electro-
development. Some types of corrosion can travel beneath chemical series. The earlier a metal appears in the
surface coatings and can spread until the part fails. series, the more easily it gives up electrons. In other
words, a metal that gives up electrons is known as an
anodic metal and corrodes easily. On the other hand,
metals that appear later in the series do not
72-6 Cleaning and Corrosion
give up electrons easily and are called cathodic met- is in contact with moisture having a trace of
als. [Figure 12-2] hydrochloric acid, a chemical reaction takes place
between the acid and the aluminum to form aluminum
Many metals become ionized due to galvanic action chloride and hydrogen.
when brought into contact with dilute acids, salts,
or alkalis, such as those found in industrially cont- 2A1 + 6HC1 -> 2A1C13 + 3H2
aminated air. For example, if an aluminum structure
Figure 12-2. The metals listed above are arranged in order of The hydrogen is released as a gas, and aluminum chloride,
which is a salt, forms as a white powder on the surface of
ELECTROCHEMICAL SERIES FOR METALS
the metal. This powder is the visible evidence of
(NOBILITY) MOST ANODIC - WILL GIVE UP corrosion.
ELECTRONS MOST EASILY.
MAGNESIUM Corrosion is an electrochemical action in which one metal
ZINC
CLAD 7075 ALUMINUM ALLOY is changed into a chemical salt. When two dissimilar
COMMERCIALLY PURE ALUMINUM (1100) metals are in contact with each other in the presence of
CLAD 2024 ALUMINUM ALLOY some electrolyte such as hydrochloric acid or plain water,
CADMIUM
7075-T6 ALUMINUM ALLOY
the less active metal acts as the cathode and attracts
2024-T3 ALUMINUM ALLOY electrons from the anode. As the electrons are pulled
MILD STEEL away from the anode the metal corrodes.
LEAD
TIN
COPPER Perhaps the easiest way to visualize what is actually taking
STAINLESS STEEL place is to consider the action of a battery. If two metals
SILVER are immersed in an electrolyte of acid, saline, or alkaline
NICKEL
CHROMIUM
solution, a battery is formed and produces a flow of
GOLD electrons between the two metals. The process continues
as long as there are active materials in the metal and
electrolyte and the cathode and anode are connected by a
electrode potential. Any metal appearing in this series is
anodic to any metal which follows it and will corrode if sub-
conductive path. [Figure 12-3]
jected to galvanic action.
 ALUMINUM COPPER

Figure 12-3. A simple battery explains the formation of corrosion, as electrons leaving the anode attract chlorine ions from the elec-
trolyte to form aluminum chloride, which is the visible evidence of corrosion.