Cleaning an aircraft and keeping it clean is important

It is the most important rule for corrosion control

Grease and dirt hold in moisture forming corrosion when it contacts aluminum.

Sacrificial corrosion, inspecting combined metal areas.

Cleaning Agents

Alog with the agents use to control corrosion can expose the aircraft technician to dangerous equipment
and chemicals that may be harmful if the skin comes in contact with the agent or they are inhaled.

Extreme care must betaken following procedures in order to mimize and prevent the potential exposure
to these chemicals.

Information on these can be found in the MSDS

Solvent cleaners are used in cleaning must have a flashpoint no less than 105f If explosion proof of
equipment and other special precautions are to be avoided.

Chlorinated solvents of all types must meet nonflammable requirements but are toxic

Carbon tetrachloride must be avoided.

Particuar attention must be paid to PPE.

DRY CLEANING SOLVENTS

Most common petroleum based solvents used in cleaning is Stoddard flashpoint above 105f, removes
grease oil light soil.

Dry cleaning solvent is preferable to kerosene for all cleaning purposes but like kerosene it leaves a slight
residue upon evaporation that may interfere with the application of some final paint films.

MIL SPEC NUMBER is used if an agent is not available anymore.

ALIPHATIC NAPTHA recommended for wipe down of cleaned surfaces before painting this material can
also be used for cleaning acrylics and rubber. Flashes around 80f and used with care.

Aromatic Naphtha must not be confused with aliphatic it is toxic attacks acrylics and rubber products and
muse be controlled adequately.

Safety Solvent.. trichloroethane is used for general cleaning and grease removal it is a nonflammable

Emulsion Type Cleaners

A chemical cleaner which mixes with water or a petroleum solvent to form an emulsion. Purpose: to
loosen dirt soot carbon and grease. Oxide films from the surface of the aircraft when used in accordance
these solvent emulsions do not affect good paint coatings or organic finishes.

Types Light or Heavy

Light agents soap and synthetic detergent types cleaners, nontoxic and nonflammable.
Heavy Duty Cleaning Agent, solvent and emulsion type cleaners, may have to be neutralized after use,
alkaline cleaner may cause corrosion.

Water Emulsion Cleaner

Material available under spec MIL C 22543A is a water emulsifying cleaning compound intended for use
on both painted and unpainted surfaces.

Solvent Emulsion Cleaners onphenolic can be safely used on painted surfaces witohith softening the base
paint. Effective in softening and lifting hevy preservative, repeated use may soften acrylics.

Phenolic Base more effective for heavy duty application but it also tends to soften paint coatings it msue
be used with care around rubber plastics or other no maettalic materials wear rubber gloves and goggles
for protection whe working with phenolic bases.

Chemical Cleaners all residue must be removed chromic acid or dichromate treatment will liquefy and
promote blistering in the paint coatings.

Non Ionic Detergent Cleaners May be either water or oil soluble

The oil soluble detergent cleaner is effective in a 3 to 5 percent solution in dry cleaning solvent for
softening and removing heavy preservavtice coatings.

MEK METHYL ETHYL KETONE is a solvent cleaner for metlal surfaces and paint stripper for small areas, it
is toxic when inhaled and safety precautions must be ovserved.

Kersone is mixed with solvent umsion type cleaners for softening heavy preservative coatiings. Used for
general solvent cleaning.

Kerosene does nog evaporate as rapidly as dry cleaning solvent and generally leaves an appreciable film
on cleaned surfaces which may actually be corrosive.

Baking soda may be used to neutralized acide deposits in lead acid battery compartments and to trat
acid burns from chemical cleaners and inhibotrs

EXTERIOR CLEANING three methods

Wet Wash removes all oil grease and carbon deposits and mose soils with the exception of corrosion an
doxide films. Applied with spray or mop after which high pressure running water is used as a rinse. Either
alkaline or emulsion cleaners can be used in the wet wash method.

DRY WASH used to remove airport film dust and small accumulations of dirt and soil when the use of
liquids is neither desirable nor practical. Is not suitable for removing heavy deposits of carbon or grease.
Materials are applied with spray mops or cloths and removed by dry mopping or wiping with clean dery
cloths.

Polishing restores the lsiter to painted and unpainted surfaces on the aircraft and performed after the
surface has been cleaned. Removes oxidation and corrosion. In various forms and degrees of
abrasiveness.
Prior to cleaning the aircraft. Install covers over all opening where water or cleaners might enter and
cause damage. Pay particular attention to instrument system components such as pitot static fittings and
ports cover any opening to prevent water from getting into the ports. The washing of aircraft should be
performed in the shade whenever possible as cleaning compounds tends to streak the surface if applied
to hot metal or are permitted to dry on the surface.

Risne the surface immediately after cleaning to prevent the compound from drying on the surface.

Various areas of aircraft such as the housing radar and the area forward of the cockpit.

Before eapplying soap to plastic flush it with fresh water to dissolve salt deposits and wash away dust
particles plastid surfaces should be washed with soap and water by hand.

Do not rub plastic with a dry cloth. No scouring powder. No acetone or benzene

Surface oil hydraulic fluid grease or fuel can be removed from aircraft tires by washing with a mild soap
solution.

After cleaning lubricarte all grease fittings hinges and so forth where removal contamination or dilution
of the grease is suspected during wshing.

Cleaning around oxygen systems. Compinds are anhydrous waterless may be used to clean accessible
components of the oxygen system such as crew masks and lines

Fluids should not be put into tanks or regulators, do not use any cleaning compounds which may leave
an oily film when cleaning oxygen equipment.

POWERPLANT CLEANING remove all cowlings start from top to bottom use emulsion cleaning, remove
deposits with bristle brush, dry with compressed air then lubricate control rods bellcranks and moving
parts.

Aircraft propellers use soap and water. Except in the process of etching caustic material must not be
used on a propeller scrapers power buffers steel brushes or any tool or substance that mar or scratch the
surface must not be sued on a propeller blades exept as recommended for etching and repair. Water
spray rain or other airborn abrasive material strikes a whirling roepller blade with such force that small
pits are formed in the vlades leading edge if preventative measures aren’t taken corrosion makes pits
larger. Steel blades have more resistance and if rubbed with oil retain a smooth surface.

INTERIOR CLEANING

Aircraft Corrosion

Metal corrosion is the deterioration of the metal by chemical or electrochemical attack

Can take place internally as wella s on the surface

This may change the smooth surface, weaken the interior or damage e and looen adjacent parts

If left unchecked can cause structural faiulure

Water or water vaport containing salt combines with oxygen in the atmosphere to produce the main
source f corrosion in aircraft,
Corrosion appearance aluminum and magnesium appears as pitting and etching often combined with a
gray or white powdery deposit

Copper corrosion forms greenish films

Steel reddish corrosion described as rust

Ferrous metals want to corrode into iron oxide because that is its natural most stable state and needs
this to take place is oxygen.

TYPES OF CORROSION

Direct chemical attack

Electrochemical attack-most common

In both types the metal is converted into a mettalic compound such as an oxide hydroxide or sulfate

The metal that is attacked or oxidized suffers what may be called anodic change and the corrosive agent
is reduced and may be considered as undergoing cathodic change.

Connected with electrolyte

Direct chemical attack is from direct exposure of a bare surface to caustic liquid or gaseous agents

Changes in direct chemical attack are occurring simultaneously at the same poinr/ the most common
agents causing direct chemical attack on aircraft are

1 spilled battery 2 residual flux deposits from welding or soldered joints 3 entrapped caustic cleaning
solutions.

ELECTROCHEMICAL ATTACK

The reaction in this requires a medium usually water which is capapable of conducting a tiny current

When a metal comes in contact with a corrosive agent and is also connected by a liquid or gaseous path
through which electrons may flow corrosion begins as the metal decays by oxidation

All metals and alloys are electrically active and have a specific electrical potential in a given chemical
environment this potential is commonly referred to as the metals nobility.

The less noble a metal is the more

Exposure of the allow to a conductive corrosive mediu causes the more active metal to become anodic
and the less active metal to become cathodic making corrosion

The greater the difference in the electrical potential between the two the more severe the corrosion will
occur. If by regular cleaning and surface refinishing the medium is removed and the minute electrical
circuit eliminated corrosion cannot occur this is the basis for effective corrosion control.

FORMS OF CORROSION

Surface Corrosion- may be caused by both attacks. Sometimes corrosion will spread under a surface
coating.
Appears as a general roughening and or etching on the surface of the metal advanced surface corrosion
will show pitting of the surface of a meal freqwuentyly acocompanied by a powdery deposit of corrosion

If corrosion is under the surface coating paint or plating is lifted off the surface in small blisters which
result from the pressure of the underlying accumulation of corrosion.

Filliform Corrosion gives the appearance of a series of small worms under the surface. It is often seen on
surfaces that have been improperly chemically treated prior to painting.

Dissimilar Metal Corrosion a galvanic action occurs at the point or areas of contact where the insulation
between the surfaces has broken down.

This electrochemical attack can be very serious because in many instances the action is taking place out
of sight and the only way to detect it prior to structural failure is by disassembly and inspection. Appears
as extensive pitting damage.

Improper use of products like steel wool or wire brush on aluminum or magnesium can force small piece
of steel into the metal being cleaned which will then further corrode and ruin adjoining surface.

INTERGRANNULAR CORROSION an attack along the grain boundaries of an alloy and commonly results
from a lack of uniformity. Aluminum alloys and some stainless steels are particularly susceptible to this
form of electrochemical attack.

The lack of uniformity is caused by changes that occur in the alloy during heating and cooling during the
material manufacturing process. Intergranular corrosion may exists without visible surface evidence.

Severe intergranular corrosion may sometimes cause the surface of a metal to exfoliate.

Stress corrosion occurs as a result of the combined effect of sustained tensile stresses and a corrosive
environment. Itusually occurs along lines of coldworking and may be intergranular or transgranualr.
Stress corrosion cracking is found in most metal systems.

Fretting corrosion occurs when two mating surfaces normally at rest with respect to one another are
subject to relative motion. Since the restricted movements of the two durfaces prevent the debris from
escaping easily an extremely localized abrasion occurs

False Brinelling small and sharp deep grooves resembling Brinell marks or pressure indentations may be
worn in the rubbing surface as a result this type of corrosion is false brinelling.

Factors. Climate conditions affect corrosion. Sea water and salty air is more detrimental to aircraft than
dry areas. Temperature considerations are important because the speed of the electrochemical attack is
increased in a hot moist climate.

Foreign Material soil and dust, oil grease and engine exhaust, sat water and moisture, spilled battery
acid, caustic cleaning materials, welding residue.

CORROSION MAINTENANCE
Adequate cleaning, frequent lubrication, detailed inspection for corrosion and failure of protective
sytems. Prompt treatment of corrosion and touchup of damage paint areas. Keeping drain holes free of
obstructions, daily draining of fuel cell sumps, daily wipe down of exposed critical areas, sealing of
aircraft against water during foul weather and proper ventilation on warmy sunny days.

Engine exhaust area is prone to corrosion

Battery compartments and battery vent fumes from overheated electrolyte are difficult to contain and
will spread adjactent

CORROSION REMOVAL

Any treatment involves cleaning and stripping of the corroded area, removing as much of the corrosion
products as practicable, neutralizing any residual materials remaining in pits and crevices, restoring
protective surface films and, applying temporary or permanent coatings or paint finishes.

Surface cleaning and paint removal

The removal of corrosion necessarily includes removal of surface finishes covering the attacked area,
must clean oil grease, this helps determine area of corrosion.

After cleaning and removing the pain on the affected area the next step is to remove the exposed
corrosion.

2in to greater than 3 in pad for mechanical removal of corrosion

Chemical removal chromic acid or sulfuric acid to treat corrosion apply with a swab or brush, scrub to
make sure it penetrates the corrosion.

Anodizing most common treatment of non clad aluminum alloy

Alodizing chemical treatment for all aluminum to increase corrosion resistance and paint bonding
qualities, clean then apply Alodine by dipping spraying or burshing

Zinc Chromate primer used on airplanes yellow in color

Removal of iron rust is using abrasive papers and compounds

Surface treatment for steel, prevent air and mosoture from reaching the metal. Cadmium plating
protects the steel.

Nickel and chrome Plating forms an airtight coating over the metal this coating will exclude air and
moisture from the base metal and prevents it from corroding.

Galvanizing protects steel by applying a coat of zinc on the steel by dipping it in a bat of molten zinc a
corrosion cell is formed between the steel and zinc

Metal spraying is molten aluminum sprayed on the surface of an engine

AIRCRAFT REGISTRATION MARKS

Size requirements must be atleast 12 inches high glider is 3 inches

Marks must be equal height two thirds wide as is high, formed by solid lines 1/6 as wide as they are high
m and w can be as wide as high

Spacing no less than ¼ character width. Must be painted or permanently affixed.

Fixed wing must be displayed on certical tail surface or sides of fuselage. If on certical tail must be
horizontal on both surfaces. If on fuselage horizontally on both sides between trailing edge of wing and
leading dge of horizontal stabilizer

On rotorcraft must be displayed on both surfces of cabin fuselage boom or tail

On airships iaw part 45

AC 45-2

Dope is a colloidal solution of cellulose acetate or nitrate combined with plasticizers to produce a
smooth flexible surface.

Synthetic Enamel is an oil based single stage paint that provides durability and protection and mixed with
hardener to increase the durability and shine while decreasing drying time it is one of the most
economical finishes

Lacquers

Nitrocellulose lacquers, polyurethane

Urethane coatings

Acrylic urethanes

Surface Prep for painting

Scrub surface with scotch brite pads using alkaline cleaner should be kept wet and rinse with cean water
until the surface is water break free.

Apply acid etch solution to the surface using a new sponge keep it wet allow area to rinse with no
solution drying on the surface when surfaces are dry apply Alodine or other coating applied like a wash
keeping wet for 2 to 5 minutes without letting it dry

\when surface turns gold and is dry primer should be applied as soon as possible. No zinc chromate if
using polyurethane paints.
Composite surfaces

Acetone hevy duty degreaser for metal prep prior to doping

Alcohol butanol or butyl alcohol mixed with dope to retard drying

Masking material use solvent proof tape do not use newspaper to mask use masking paper

Blushing is when dull milky haze appears in paint surface and when moisture gets in paint

Pinholes are tiny holes that appear in the surface finish as a result of trapped solvent air or moisture

Sags and runs caused by too much paint on the surface by holding can too close to the surface or moving
the gun to slowly across the surface

Orange Peel- the appearance of a bumpy surface much like the skin of an orange it can be the result of a
number of factos with the first being iproper adjustment of the spray gun, not enough reducer too thick
or the wrong type of recuder for the temperature material not uniformily mixed forfed drying method
either with fans or heat too wuick

To little flas time between coats spray paint when when the ambient subrstrate temp is either too hor or
too cold

Wrinkling caused by trapped solvent and uneven drying

Spray dust caused by atomized spray particles from the gun becoming dry before reaching the surface
being painted caused by incorrect air pressure pattern flow too close or far from surface material
improperly being thinned.

Working rivet is a loose rivet and develops a paste around the areas that it moves.

Radial play is side to side, Axial is play that is up and down.

Rivets in exhaust area of aircraft

4 examples of corrosion, location, interior/exterior

How to treat and remove each type, tools

285.9 in station