Corrosion Control in the Aerospace Industry

Corrosion control in the aerospace industry has always been important, but is becoming more so with the ageing of the aircraft fleet. Corrosion control in the aerospace industry provides a comprehensive review of the subject with real-world perspectives and approaches to corrosion control and prevention. Part one discusses the fundamentals of corrosion and the cost of corrosion with chapters on such topics as corrosion and the threat to aircraft structural integrity and the effect of corrosion on aluminium alloys. Part two then reviews corrosion monitoring, evaluation and prediction including non-destructive evaluation of corrosion, integrated health and corrosion monitoring systems, modelling of corrosion and fatigue on aircraft structures and corrosion control in space launch vehicles. Finally, Part three covers corrosion protection and prevention, including chapters which discuss coating removal techniques, novel corrosion schemes, greases and their role in corrosion control and business strategies in fleet maintenance. With its distinguished editor and team of expert contributors, Corrosion control in the aerospace industry is a standard reference for everyone involved in the maintenance and daily operation of aircraft, as well as those concerned with aircraft safety, designers of aircraft, materials scientists and corrosion experts. Discusses the fundamentals of corrosion and the cost of corrosion to the aerospace industry Examines the threat corrosion poses to aircraft structural integrity and the effect of corrosion on the mechanical behaviour of aircraft Reviews methods for corrosion monitoring, evaluation and prediction examining both current practices and future trends

Corrosion is a huge issue for materials, mechanical, civil and petrochemical engineers. With comprehensive coverage of the principles of corrosion engineering, this book is a one-stop text and reference for students and practicing corrosion engineers. Highly illustrated, with worked examples and definitions, it covers basic corrosion principles, and more advanced information for postgraduate students and professionals. Basic principles of electrochemistry and chemical thermodynamics are incorporated to make the book accessible for students and engineers who do not have prior knowledge of this area. Each form of corrosion covered in the book has a definition, description, mechanism, examples and preventative methods. Case histories of failure are cited for each form. End of chapter questions are accompanied by an online solutions manual. * Comprehensively covers the principles of corrosion engineering, methods of corrosion protection and corrosion processes and control in selected engineering environments * Structured for corrosion science and engineering classes at senior undergraduate and graduate level, and is an ideal reference that readers will want to use in their professional work * Worked examples, extensive end of chapter exercises and accompanying online solutions and written by an expert from a key pretochemical university

Corrosion is an expensive and potentially dangerous problem in many industries. The potential application of different nanostructured materials in corrosion protection, prevention and control is a subject of increasing interest. Corrosion protection and control using nanomaterials explores the potential use of nanotechnology in corrosion control. The book is divided into two parts. Part one looks at the fundamentals of corrosion behaviour and the manufacture of nanocrystalline materials. Chapters discuss the impact of nanotechnology in reducing corrosion cost, and investigate the influence of various factors including thermodynamics, kinetics and grain size on the corrosion behaviour of nanocrystalline materials. There are also chapters on electrodeposition and the corrosion behaviour of electrodeposited nanocrystalline materials. Part two provides a series of case studies of applications of nanomaterials in corrosion control. Chapters review oxidation protection using nanocrystalline structures at various temperatures, sol- gel and self-healing nanocoatings and the use of nanoreservoirs and polymer nanocomposites in corrosion control. With its distinguished editors and international team of expert contributors, Corrosion protection and control using nanomaterials is an invaluable reference tool for researchers and engineers working with nanomaterials in a variety of industries including, aerospace, automotive and chemical engineering as well as academics studying the unique protection and control offered by nanomaterials against corrosion. Explores the potential use of nanotechnology and nanomaterials for corrosion prevention, protection and control Discusses the impact of nanotechnology in reducing corrosion cost and investigates various factors on the corrosion behaviour of nanocrystalline materials Provides a series of case studies and applications of nanomaterials for corrosion control

Corrosion control in the aerospace industry is becoming more important with the ageing of the aircraft fleet. In the recent years, aviation industry in terms of corrosion has been undertaken with million pounds. Corrosion control can be one of the aircraft industry's most effective weapons in the battle against airplane structural failures. Left undetected and/or untreated, corrosion can decrease the load carrying capacity of primary structures or act as nucleation sites for fatigue or stress corrosion cracks. Thus corrosion can undermine the integrity of an aircraft and make it unsafe to fly. Therefore, by appropriate maintenance and husbandry, these effects could be decreased. Most of the aircrafts could be maintained by long term and short term inspection check. Nowadays, one of the most important and yet most underestimated support activities for corrosion control in aviation industry is protective coating. Airframe problems associated with corrosion have plagued the aviation industry for decades. The metals that compose aircraft components are subject to several different forms of corrosion, a process accelerated by many factors including prolonged exposure to corrosive agents like industrial fluids, salts, and moisture, or more internal problems such as condensate formation and leaking lavatories and galleys. Some forms of corrosion such as stress corrosion cracking and corrosion fatigue can lead to catastrophic failure if not detected and treated. This volume Corrosion Control in the Aerospace Industry provides a comprehensive review of the subject with real-world perspectives and approaches to corrosion control and prevention. It presents the coverage of the fundamentals of corrosion and the threat to aircraft structural integrity and the effect of corrosion on aluminum alloys. Furthermore, it examines corrosion assessment, evaluation and control including non-destructive estimate of corrosion, incorporated health and corrosion monitoring systems, modeling of corrosion and fatigue on aircraft constructions and corrosion control in space vehicles. This book will appeal to students studying in aircraft maintenance engineering or everyone involved in the maintenance and daily operation of aircraft in addition to those associated with aircraft protection, aircraft designers, materials scientists and corrosion specialists.

This volume covers the various sensors related to automotive and aerospace sectors, discussing their properties as well as how they are realized, calibrated and deployed. Written by experts in the field, it provides a ready reference to product developers, researchers and students working on sensor design and fabrication, and provides perspective on both current and future research.

Coatings are used for a wide range of applications, from anti-fogging coatings for glass through to corrosion control in the aerospace and automotive industries. Nanocoatings and ultra-thin films provides an up-to-date review of the fundamentals, processes of deposition, characterisation and applications of nanocoatings. Part one covers technologies used in the creation and analysis of thin films, including chapters on current and advanced coating technologies in industry, nanostructured thin films from amphiphilic molecules, chemical and physical vapour deposition methods and methods for analysing nanocoatings and ultra-thin films. Part two focuses on the applications of nanocoatings and ultra-thin films, with chapters covering topics such as nanocoatings for architectural glass, packaging applications, conventional and smart nanocoatings for corrosion protection in aerospace engineering and ultra-thin membranes for sensor applications. With its distinguished editors and international team of contributors, Nanocoatings and ultra-thin films is an essential reference for professional engineers in the glazing, consctruction, electronics and transport industries, as well as all those with an academic research interest in the field. Provides an up-to-date review of the fundamentals, processes of deposition, characterisation and applications of nanocoatings Focuses on the applications of nanocoatings and ultra-thin films, covering topics such as nanocoatings for architectural glass, packaging applications and ultra-thin membranes for sensor applications Includes chapters on current and advanced coating technologies in industry, nanostructured thin films from amphiphilic molecules, chemical and physical vapour deposition methods and methods for analysing nanocoatings and ultra-thin films

This book presents selected contributions to the Symposium of Aeronautical and Aerospace Processes, Materials and Industrial Applications of the XXV International Materials Research Congress (IMRC). Each chapter addresses scientific principles behind processing and production of materials for aerospace/aeronautical applications. The chapter deals with microstructural characterization including composites materials and metals. The second chapter deals with corrosion in aerospace components is a large and expensive problema for aerospace industry. Finally, the last chapter covers modeling and simulation of different processes to evaluate and optimize the forming process. This book is meant to be useful to academics and professionals.

This encyclopedia, written by authoritative experts under the guidance of an international panel of key researchers from academia, national laboratories, and industry, is a comprehensive reference covering all major aspects of metallurgical science and engineering of aluminum and its alloys. Topics covered include extractive metallurgy, powder metallurgy (including processing), physical metallurgy, production engineering, corrosion engineering, thermal processing (processes such as metalworking and welding, heat treatment, rolling, casting, hot and cold forming), surface engineering and structure such as crystallography and metallography.

The aerospace industry is constantly looking for methods to reduce the cost of flying their airplanes. These savings can come in many forms, one of them being cost savings attributed to fuel savings by either reducing the weight of the airplane or reducing the drag. Friction stir welding (FSW) was introduced as a means of joining previously unweldable Al 7075, a high-strength aluminum alloy commonly used in aerospace for its high specific strength. This eliminated the need for costly and time consuming rivets to be installed, firstly reducing the production cost of the airplane and secondly reducing the overall weight of the airplane therefore improving fuel consumption. There are many factors at play in the process of producing FSW Al 7075, but the result of this process creates a weld joint that is more susceptible to corrosion than the rest of the panel. For this reason, FSW Al 7075 panel fail prematurely and must be replaced too often. The main goal of this project is, using cold gas dynamic spray, to create a metallic layer on top of an Al 7075 FSW joint to protect it against corrosion. A series of 3 corrosion tests indicated that pure Al, among coatings of pure Al, Al 5038 and Al 7075, offered the best protection against corrosion. Al 5083 would also be a suitable material and should be used in applications where high bond strengths are required. Al 7075, although of the same alloy as the parent material, is not recommended for corrosion protection as it offered little advantage over the parent material. In order to better understand the interaction of creating a coating after a hot welding process, several analyses were performed. These included deposition at multiple substrate temperatures as well as hardness and velocity measurements. Results indicate that some aluminum alloys are very sensitive to temperature, yielding better coatings at high substrate temperatures. Individual particle deposition tests reveal that these improvements do not occur at the substrate-coating interface. Another portion of this project was dedicated to creating tensile specimens composed entirely of pure Al cold sprayed coatings. Several sets of samples were produced. Results indicate that pulling in the direction of nozzle travel direction yields UTS values 50% higher than pulling in the direction perpendicular to the direction of nozzle travel during coating deposition. Results after annealing seem to converge towards the same value. Finally, a new nozzle design was performed which should create a more efficient spraying process, resulting in cost savings for the industry.

The major objective of this book was to identify issues related to the introduction of new materials and the effects that advanced materials will have on the durability and technical risk of future civil aircraft throughout their service life. The committee investigated the new materials and structural concepts that are likely to be incorporated into next generation commercial aircraft and the factors influencing application decisions. Based on these predictions, the committee attempted to identify the design, characterization, monitoring, and maintenance issues that are critical for the introduction of advanced materials and structural concepts into future aircraft.

This memorandum deals with the corrosion protection of magnesium and magnesium alloys. The corrosion resistance of these alloys in many natural environments, while not as good as that of copper, nickel, stainless steel, and aluminum, is in the same range as that of the iron and plain carbon steels. Some type of additional corrosion protection is often necessary and, as with steel, the protective measures usually involve some type of coating system and/or surface treatments. Also, magnesium can suffer accelerated attack when coupled, in the presence of a conductive electrolyte, to most metals below it in the galvanic series. This galvanic effect complicates the problem of corrosion protection. A number of coating systems have been proposed and used satisfactorily. Depending upon the application, these coating systems include the use of conversion coatings, organic coatings, metallic coatings, and others. In addition, special designs can be employed to improve the over-all corrosion resistance of the systems. This memorandum describes many of the coating systems and design methods which are used to reduce corrosive attack on both galvanically coupled and uncoupled magnesium assembliesd (Author).

The classic book on corrosion science and engineering—now in a valuable new edition The ability to prevent failures by managing corrosion is one of the main global challengesof the twenty-first century. However, most practicing engineers and technologists have only a basic understanding of how they can actively participate in this urgent economic and environmental issue. Now, students and professionals can turn to this newly revised edition of the trusted Corrosion and Corrosion Control for coverage of the latest developments in the field, including advances in knowledge, new alloys for corrosion control, and industry developments in response to public demand. This Fourth Edition presents an updated overview of the essential aspects of corrosion science and engineering that underpin the tools and technologies used for managing corrosion, enhancing reliability, and preventing failures. Although the basic organization of the book remains unchanged from the previous edition, this new update includes: An introduction to new topics, including the element of risk management in corrosion engineering and new advanced alloys for controlling corrosion Expanded discussions on electrochemical polarization, predicting corrosion using thermodynamics, steel reinforcements in concrete, and applications of corrosion control technologies in automotive, nuclear, and other industries A stronger emphasis on environmental concerns and regulations in the context of their impact on corrosion engineering A discussion of the challenge of reliability in nuclear reactors; stainless steels; the concept of critical pitting temperature; and information on critical pitting potential (CPP) Complemented with numerous examples to help illustrate important points, Corrosion and Corrosion Control, Fourth Edition enables readers to fully understand corrosion and its control and, in turn, help reduce massive economic and environmental loss. It is a must-read for advanced undergraduates and graduate students in engineering and materials science courses, as well as for engineers, technologists, researchers, and other professionals who need information on this timely topic.

Intelligent Coatings for Corrosion Control covers the most current and comprehensive information on the emerging field of intelligent coatings. The book begins with a fundamental discussion of corrosion and corrosion protection through coatings, setting the stage for deeper discussion of the various types of smart coatings currently in use and in development, outlining their methods of synthesis and characterization, and their applications in a variety of corrosion settings. Further chapters provide insight into the ongoing research, current trends, and technical challenges in this rapidly progressing field. Reviews fundamentals of corrosion and coatings for corrosion control before delving into a discussion of intelligent coatings—useful for researchers and grad students new to the subject Covers the most current developments in intelligent coatings for corrosion control as presented by top researchers in the field Includes many examples of current and potential applications of smart coatings to a variety of corrosion problems

Magnesium alloys are widely used in aircraft and automotive components because of their inherent light weight compared to other engineering metals. However, premature corrosion is one of the challenges associated with magnesium. In the aerospace industry, many expensive castings cannot be reclaimed adequately because current methods are often inappropriate due to excessive porosity, oxidation and thermal damage. Cold spray is a solid-state coating process that uses a supersonic gas jet to accelerate small particles against a substrate to produce metal bonding by rapid plastic deformation of the impacting particles. Significantly, magnesium components can be repaired, restored and protected by cold spray deposition of pure aluminum which has thus already been specified by some aerospace users as a standard technique for magnesium repair. In this chapter, the state of the art of commercial cold spray technologies for magnesium repair will be discussed, as well as their advantages and limitations compared to traditional thermal processes.

This book serves as a comprehensive resource on metals and materials selection for the petrochemical industrial sector. The petrochemical industry involves large scale investments, and to maintain profitability the plants are to be operated with minimum downtime and failure of equipment, which can also cause safety hazards. To achieve this objective proper selection of materials, corrosion control, and good engineering practices must be followed in both the design and the operation of plants. Engineers and professional of different disciplines involved in these activities are required to have some basic understanding of metallurgy and corrosion. This book is written with the objective of servings as a one-stop shop for these engineering professionals. The book first covers different metallic materials and their properties, metal forming processes, welding, and corrosion and corrosion control measures. This is followed by considerations in material selection and corrosion control in three major industrial sectors, oil & gas production, oil refinery, and fertilizers. The importance of pressure vessel codes as well as inspection and maintenance repair practices have also been highlighted. The book will be useful for technicians and entry level engineers in these industrial sectors. Additionally, the book may also be used as primary or secondary reading for graduate and professional coursework.

Chromate-based technology used currently in the aerospace industry provides excellent corrosion protection for the aerospace metals and alloys such as AA 2024-T3. However, chromates are toxic and carcinogenic and the Environmental Protection Agency of the United States has identified chromates for replacement. This has resulted in a global research effort to find an effective alternative.