Corrosion is one of the most significant threats to an aircraft’s structural integrity and long-term performance and therefore needs effective corrosion treatment. For aircraft owners and operators, maintaining the integrity of the aircraft is a top priority, and corrosion treatments are key to ensuring this. Safety, and reliability are paramount for any aircraft owner and ensuring that corrosion is effectively treated is essential.
In this blog, we will take you through what corrosion treatment is, how it’s done, and where it’s typically performed. We will answer any of your questions around corrosion treatment and how it can benefit your aircraft. Let’s get stuck in.
What is Corrosion Treatment?
Corrosion treatment involves the identification, removal, and prevention of corrosion on an aircraft. Corrosion occurs when metal parts of the aircraft react with moisture, salt, oxygen, or other environmental factors, leading to the deterioration of the material. This can weaken key components of the aircraft, posing safety risks and reducing the lifespan of critical structures.
In executive aircraft refurbishment, corrosion treatment plays a crucial role in restoring the aircraft to its optimal condition, ensuring both the safety of the passengers and the longevity of the airframe.
Why is Corrosion Treatment Necessary?
While modern aircraft are designed to withstand the harshest environmental conditions, exposure to moisture, salt (from oceanic routes), and other corrosive elements can cause significant damage over time. If left untreated, corrosion can spread and compromise the structural integrity of the aircraft, potentially leading to expensive repairs or even catastrophic failures.
By investing in proper corrosion treatment, aircraft owners can ensure:
- Increased lifespan of the airframe and components
- Enhanced safety for passengers and crew
- Reduced maintenance costs in the long run
- Preservation of aircraft value for resale or lease
How is Corrosion Treatment Done?
Corrosion treatment is a multi-step process that requires meticulous attention to detail. Here are the main steps involved:
Inspection and Assessment
The first step is a comprehensive inspection of the aircraft’s body and internal components. This is done using a combination of visual checks, ultrasonic testing, and specialised equipment to detect hidden corrosion in critical areas like the fuselage, wings, tail, and landing gear.
Corrosion Removal
Once corrosion is identified, it needs to be removed. Depending on the severity, this can be done through abrasive blasting, chemical stripping, or sanding. For mild corrosion, light sanding may suffice, while heavier corrosion may require more intensive measures like media blasting.
Surface Preparation
After the corrosion is removed, the affected area must be thoroughly cleaned and prepared for treatment. This may involve washing the surface, removing debris, and applying a primer to prevent further corrosion. Proper surface preparation is crucial for ensuring that the treatment is effective and long-lasting.
Corrosion Protection
The final step is applying anti-corrosion coatings or treatments. This can include:
- Zinc-rich primers that create a sacrificial barrier to prevent corrosion from forming.
- Epoxy coatings that offer long-lasting protection against moisture.
- Anodising for aluminium parts to increase corrosion resistance.
- Sealants to prevent moisture from ingress into joints and seams. These treatments act as a protective barrier, safeguarding the aircraft from future corrosion and extending the lifespan of metal components.
Post-Treatment Inspection
After the treatment is applied, the aircraft undergoes a final inspection to ensure that the corrosion protection has been properly applied and that the aircraft is free of any remaining signs of corrosion.
Where is Corrosion Treatment Done on the Aircraft?
Corrosion can affect many areas of an aircraft, particularly those exposed to the harsh elements during flight and operation. The locations where corrosion is most commonly found are critical to the safety and performance of the aircraft. Effective corrosion treatment focuses on these high-risk areas, ensuring that structural integrity is maintained and the aircraft continues to meet the highest safety standards.
Fuselage and Skin
The fuselage, or the main body of the aircraft, is especially vulnerable to corrosion, particularly around seams, rivets, and joints where moisture can accumulate. The aircraft’s outer skin is also exposed to the elements, including rain, saltwater, and other corrosive substances encountered during flight, especially over oceans. Corrosion treatment on the fuselage typically involves cleaning, stripping, and applying protective coatings to prevent further deterioration.
Wings and Wing Spars
The wings are one of the most critical structural components of the aircraft, and corrosion here can affect both the aircraft’s aerodynamics and safety. The wing spars, which are the main load-bearing members of the wing, are particularly susceptible to corrosion because of their exposure to environmental stressors like moisture and air pressure. Treatment focuses on these areas to ensure strength and airworthiness.
Empennage (Tail Section)
The tail section, or empennage, is another area prone to corrosion due to its exposure to airflow and moisture. This includes the horizontal stabiliser and vertical stabiliser, as well as the rudder and elevators. Corrosion treatment is especially important in these areas to ensure that the aircraft maintains proper control and stability during flight.
Landing Gear and Associated Components
The landing gear is one of the most corrosion-prone areas of the aircraft, particularly because it regularly comes into contact with water, dirt, and other contaminants on the runway. Salt from coastal areas or de-icing fluids used in colder climates can also contribute to corrosion. Treatment involves cleaning and applying anti-corrosive coatings to the landing gear, brake assemblies, and surrounding components to ensure that these critical parts perform safely and reliably.
Engine Components and Nacelles
The engines and nacelles (the housing around the engines) are susceptible to corrosion from exposure to extreme temperatures, fuel, and moisture. While engine parts are generally made from high-strength alloys, proper corrosion protection is essential to prevent degradation that could affect performance or lead to premature wear. Corrosion treatment for these parts includes regular inspections, cleaning, and specialised coatings that protect against fuel, oil, and other corrosive agents.
Interior Components (Floorboards, Bulkheads, and Framework)
While the exterior of the aircraft often gets the most attention, corrosion can also occur inside the cabin, particularly on floorboards, bulkheads, and structural framework. These areas may not be as exposed to the elements but are still vulnerable to moisture, particularly in high-humidity environments or from spilled liquids. Corrosion treatment for interior components focuses on ensuring that these areas remain strong and free of rust that could compromise the overall structure.
Electrical Components and Wiring
Electrical wiring, connectors, and other sensitive electronic components are also at risk for corrosion, especially if they are exposed to moisture or if there is inadequate sealing. Corrosion of electrical components can lead to short circuits, system malfunctions, or even complete failure. Specialised anti-corrosion treatments are used on these components to prevent electrical issues and ensure the safe operation of avionics systems.
The Bottom Line
Corrosion is an inevitable challenge for aircraft owners, especially those operating in coastal or humid environments. However, with proactive corrosion treatment, it’s possible to significantly reduce the impact and ensure that your aircraft remains safe, reliable, and valuable for years to come.
If your aircraft is due for a refurbishment or corrosion treatment, working with an experienced and reputable aviation refurbishment specialist is crucial. By taking the necessary steps to address corrosion early, you’ll protect both your investment and the safety of your passengers.
At Executive Aircraft Refurbishment, we specialise in comprehensive corrosion treatments that enhance the performance and longevity of your aircraft. Contact us today to schedule a consultation and ensure your aircraft stays in top shape!
