CORROSION CONTROL

TUJUAN KURIKULER:
AGAR SISWA MENGETAHUI TENTANG
CORROSION CONTROL
INSPEKTOR HARPESBANG A- 75
 CORROSION CONTROL
Korosi : kerusakan materiel logam karena reaksi kimia
atau elektrokimia dengan lingkungan
sekitarnya

: tumbuh subur pada aspek kimia dan

mekanis lingkungan serta dpt sebabkan
kerusakan struktural parah tanpa peringatan

: logam cenderung kembali ke keadaan

aslinya ( kecuali emas dan platinum)

: Berawal dari permukaan logam

Faktor sebab korosi:
● Temperatur: semakin tinggi temperatur, reaksi
kimia akan semakin cepat, korosi akan semakin
cepat terjadi

● pH: pH yang optimal maka korosi akan semakin

cepat ( mikroba )

● Kadar Oksigen: semakin tinggi kadar oksigen

suatu tempat, reaksi oksidasi akan mudah
terjadi shg akan pengaruhi laju reaksi korosi

● Kelembaban udara,

● Man-made ( Heat treatment, Mechanical stress )

dll.....
Factors Affecting Corrosion
1. Metals contact 5. Oxygen presence
2. Temperature 6. Biological
presence
3. Time 7. Mechanical stresses
4. Electrolyte strength (pH) 8. Heat treatment
Types of Corrosion:

1. Uniform Surface Corrosion:

permukaan logam tdk terlindungi, pada bagian yang
mengandung asap dari batt, gas\exhaust, atau
kontaminasi industri

Ciri-ciri :
1. Kerusakan seragam pada material.
2. Penampakan buram.
3. Pada besi hasil korosi berwarna kemerah2an
4. Jika dibersihkan , permukaan logam mengkilap lagi
2. Pitting Corrosion:
Commonly found on Al. & Mg but can occur in other
metal alloys. Ditandai adanya endapan spt tepung
putih atau abu-abu di permukaan logam.
3. Galvanic Corrosion:
● Corrosion of dissimilar metals contact
● terjadi ketika dua macam logam yang berbeda
berkontak secara langsung dalam media
korosif.
4. Intergranular Corrosion/intercrystalline Corrosion/
Korosi Interdendritik

Caused by different size of metal’s grain, because of

improper heat treatment or adding other element
during alloying  this will change the anode &
cathode ratio where grain boundaries become anodic
on inside grain become cathodic.
5. Exfolition Corrosion:

advance stage of intergranular corrosion, caused

by remaining powdery that give pressure between
grains  separate/ delaminate the grain layers
6. Stress Corrosion:

● Terjadi saat logam terkena tensile stress

● Ketidaktepatan quenching setelah heat treatment
● Residual stress, external load
7. Corrosion Fatigue:
terjadi karena logam mendapatkan beban siklus yang
terus berulang sehingga smakin lama logam akan
mengalami patah karena terjadi kelelahan logam
Corrosion fatigue failure occurs in two stages:
● During the first stage, corrosion and cyclic stress
severely damage the metal by pitting and crack
formation.
● The second stage is propagation of the crack,
often spreading from corrosion pits.
8. Crevice/ concentration cell corrosion=electrolyte
trapped inside a gap/ a crevice will create different
potential in charge. 3 types
- Metal ion concentration cells
- Oxygen concentration cells
- Active/ passive cells
9. Filiform corrosion/underneath film corrosion:
when a protective paint coating has a scratch or
break, electrolyte will male contact and entering
metal underneath will form a corrosion like worm.
10. Fretting corrosion:
concentration cell corrosion & surface
wear combination where heavily loaded
static joints & vibration. (lubrication as
prevention)
Corrosion Prone Areas
1. Steel fasterners 8. Piano hinges
2. Spot welded 9. A/C lavatory
3. Faying surfaces 10. Water entrap.
4. Exhaust & gun blast areas 11. Battery comp.
5. Wheel well & L/G areas 12. Magnesium
6. F/C 13. Elect. connectors
7. E/G frontal area, inlet, LE
CPCs = Corrosion Prevention & Controls = control the
electrolyte by placing a barrier and also a lubricant.
Types of corrosion = light (up to 0.001”depth),
moderate (0.001”-0.010” depth), severe (more than
0.010”)
Types of CPC=Operational Preservation (day-to-day
app., light) & Non-operational Preservation (for long
periods or storage, thicker)
Major Categories CPC=Water Displacing (to remove
electrolytes & stop corrosion products for not more
than 1 month-WD40), Non-Water Displacing(thick app.
& not for dry surfaces)
CPC for small components=dipping method
 CC, Applications and Removal of Coatings
𖤓 Unit 1. Removal of Coatings. T.O. 1-1-8 outlines
specifications, procedures, materials & equipment needed
for the paint removal process.
Removal Preparations
1. Inspect all surfaces for grease, oil, dirt
2. After washing, surfaces shall be wiped dry
3. Protect all special areas & equipment
4. Positioned A/C or components in a covered facility
Two methods of removal = chemical paint removal &
mechanical paint removal
- Chemical paint removal = hazardous & not environment
friendly, no usage on advance composite.
- Mechanical paint removal = recommended (USAF) due to
structural complexities or environment restrictions.
Using hand-held abrasives. Abrasive paper (120 grit for
topcoat removal, 240 grit for primer removal), abrasive
mats (B grade fine for primer, C grade medium for
topcoat), metallic wool, wire brushes  be careful of
galvanic corrosion
Using Motor-Driven Abrasives
Make sure to check these informations
- The type of coating
- The age of coating
- The env. elements exposed on coating
- Motor driven wire brushes, abrasive flap brushes & sand blasting
SHALL NOT be used for finish removal on aluminum substrates
Random Orbital Dual Action Sander = must be triggered OFF the
surfaces and stopped OFF the surfaces. This method provides the
fastest removal rate with the least possibility of daage to the
metal substrate
Pneumatic drill also can be used with wire brushes, flap brush,
sanding pads, nylon mats or abrasive wheels.

NOTE = abrasives & attachments must be rated HIGHER than the

op. speed of the tool driving them.
Before sanding coating from any advanced composite, you
MUST know the material composition of the substrate.
Clean-up with HEPA (High Efficiency Particulate Air) vacuum
or compressed air (not more 30 psi).
Use PPE during paint removal = nitrile gloves, air purifying
respirator, ear plugs, safety goggles, tyvek/ cotton coveralls,
safety toe boots.
PMB (Plastic Media Blasting) is the preferred method for
paint removal (topcoat only). By spraying small plastics with
high speed velocity equipment.
Plastic media for coat removal (particle size 20-40 mesh)
Type I, Polyster; Type II, Urea formaldehyde; and Type III,
Melamine formaldehyde. Type IV, phenol formaldehype, a
thermoset; and Type V, Acrylic, a thermoplastic. Type VI,
poly allyl diglycol carbonate, a thermoset. Type VII Starch g
Acrylic
Blasting Cabinet
3 major component= metal cabinet
(glove box), blast/reclaimer assy
(provide the air pressure &
continuous cycle with 2 gallons on
system, with cyclone separator),
dust collector (contain blower that
removes aiborne particles from the
cyclone separator)
Blasting Booth Unit
Similar to blasting cabinet but much larger in size & volume.
Air purifying pump attached because hazardous breathing
environment.
Blast/ reclaimer assy, dust collector assy, blasting booth
 Blasting Parameter
1. Substrate type = metallic or Non-metallic
2. Media type = the media type
3. Equipment type = booth or cabinet blaster
4. Nozzle pressure = pressure at the nozzle end
5. Stand-off distance = blast distance
6. Impingement angle = angle of blaster
7. Dwell time = how fast/ slow the blaster nozzle
USAF usually type V with nozzle pressure 25-40 PSI, distance 3-5” for
cabinet or 12-24” for booth, 30-90 non-clad
𖤓 Unit 2. Corrosion Treatment
Purpose = to passivate metal, chemically treat a metal surface in
order to form a protective coating on its surface and its chemical
activity  improve corrosion resistance & adhesion of coatings

STEPS
1. Surface preparation. Wet sanding surface if needed, cleaning,
dual-wipe method, water break test, clean it again with dual-wipe
method
2. Apply passivation with chromate conversion coating MIL-C-5541/
81706 or ALODINE for 1-5 minutes
3. Rinse it with water without brushing it (brassy yellow color)
4. Dry it for 2 hours or 1 hour at 140 F max
5. Coat the surface with primer within 48 hours, if exceeded apply
another alodine
𖤓 Unit 3. Protective Coatings.
Paint Spray used by USAF = High Volume Low Pressure
(HVLP) Spray because of better for the environment
due to overspray reduction & also save money (low
maintenance)
This is a mechanical device for atomizing (breaking up)
coating material (paint) into a spray.
Using main line pressure 40-60 PSI, pressure entering
gun 20 PSI and pressure 1-10 PSI on the nozzle is used
to atomize the coating material
3 Types - Suction Feed
- Pressure Feed
- Gravity Feed
Disadv. for suction & gravity is the small capacity of 1
quartz, but very efficient for small area. USAF commonly
use suction feed for painting small area
 Nozzle Assy
1. Air cap = wing ports (horns) push air out, the direction of wing ports
same as direction of paint travel, rotate 90 degree to change the
direction
2. Fluid Tip = pushes coating material out, mix fluid with air to atomize
fluid
Fluid needle= should come as matched set with fluid tip (same
Spray pattern (spreader) adjustment screw = located
at rear, righty tidy (decrease pattern width) lefty loosy
(increase pattern width)
Fluid needle adjustment screw = right/ clock wise to
decrease flow and left =/ counter clock wise to
increase flow of fluid
INSPECTION must be done before using spray gun!
Defective hoses & couplings, loose connections, loose
air cap, cleanliness, proper seating of needle
 Spray Gun Cleaning
1. Manual Cleaning
- Unscrew air cap & release the part cup 1-2”
- Place cloth over the air cap squeeze the trigger
- Clean with thinner or solvent
- Remove & empty the cup, clean with thinner
- Clean any difficult areas
- Soak with thinner & wipe the entire gun
- Clean the air nozzle using the bristle brush
- Reassemble the gun
- Spray thinner from the gun
- Remove any excessive thinner
- Lubricate the needle & other components
2. Cleaning with spray gun cleaning unit. Turn on at 50
PSI for 1-5 minutes. Not as clean as manual.
 Disposal of painting or thinner
Safety PPE must be used
Select correct waste barrel
Ensure the container is grounded
Open the container slowly to release pressure
Pour material slowly
Remove any spilled material
Seal the barrel when completed
PAINT DEFECTS = paint is an easy task but
accomplishing this task well with no
defects can be another story
Before apply any paint, check TO for the
paint’s viscocity. Use ZAHN CUP to check
the viscocity
A lot of paint defects are because of
improper surface treatment
 Paint Defects Caused by Improper Surface
- Pin hole cavities=dirty surface, incompatile thinner,
insufficient primer
- Peeling=failed to remove water, oil, grease
- Blistering=moisture, incompatile thinner
- Fisheyes=remaining silicone
- Pitting/Cupping=resembles fisheye, corrosion left on
surfaces, moisture, water, oil, grease
- Crazing/mud cracking/checking=painting over hard glossy
coat, too much catakyts, too much heat, insusfficient drying
time between coats
- Sandpaper finish=unsatisfactory primer, spray too far from
the surface, dirt
 Paint Application Techniques
-Do not arc or wave
-Stay 90 degree

X
-6-10”
-Proper trigerring (full)
-Maintain speed
-50% overlap
 False technique paint defect
- Run & Sags = dirty air cap & fluid tip, not releasing the
trigger, strooking too close, gun not at 90 degree, cold
coat material, too much coating applied
- Streaking = not overlapping, not maintaining 90
degree, air pressure too high
- Orange Peel = coating material too cold, wrong air cap/
fluid nozzle, strooking too far, overspray, insufficient
air pressure, too thick coating. This is also become the
main reason why you must always check the viscosity
when mixing paint
  Equipment adjustment
Always conduct adjustment to your spray gun before
using it! Spray pattern adjustments, fluid adjustments,
spray pattern defects
1. Heavy Center = pattern too small, low atomizing
pressure, fluid pressure too high, air nozzle too large
2. Split Spray = atomizing pressure high, fan pattern too
wide
3. Heavy top, bottom, right/left = air cap clogged, dirt on air
cap
 Coating Application
Surface Preparation = check TO 1-1-8 for surface prep.
procedures. Clean the surface properly same as cleaning before
apply alodine. Apply alodine for bare metal. If it is painted, scuff
sanding with 120 grit silicon carbide sandpaper. If it is primed
surface, make sure the prime was done 5-8 hours before (TO 1-1-
8). If it is between 8-24 hours, reactivate the primer with
approved solvent. If it is more than 24 hours, scuff sanding with
320-400 grit sandpaper.
Coating Preparation = good painting will last for 5-8 years. USAF
use epoxy primer MIL-PRF-23377 primer with two parts, part A is
an epoxy primer and part B is polyamide curing agent (catalyst).
Agitate the resin 3-5 minutes (mechanical paint shaker is
recommended).
Dwell the mix for 30 minutes and check the viscosity. A Zahn Cup
require 17-23 seconds. If it is too thick  thinner (MIL-T-81772
Type II). Never mixed product for application in 4-hour period
Topcoat preparation = check -23 TO for proper color.
The first digit denotes the paint’s glossiness, 1=Gloss,
2=Semi-gloss, 3=Flat
Second digit denotes the paint color
Last three digit denotes the shade, higher number lighter
the shade of color. Never mixed product for application in 4-
hour period. Agitate the paint for 3-5 minutes, check the
viscosity where a Zahn Cup require 17-23 seconds. Use
thinner MIL-T-81772 Type I if it is needed.
> The catalyst of polyurethane topcoat contains 1%
hexamethylene diisocyanate = skin irritant  gloves & face
shield
Primer application = single coat 1 – 1.5 mils wet film
thickness (WFT) or 0.6 to 0.9 dry film thickness (DFT). 1 mil
= 0.001” = 0.025 mm
Primer must sit for 5 hours at 75 F and then ready to apply
top coat
Topcoat application = tag rack before apply top coat. Apply
the top coat in one wet cross coat or two cross coats with
the second coat applied crosswise (perpendicular) to the
first after curing for 4 hours apply a single coat 3.4 – 4.6 mils
wet film thickness at 50% solids volume or 1.7 to 2.3 mils
dry film thickness
  Minimum cure times (@75 F)
1. Before handling, taping, masking 6 hrs
2. Before movement from controlled env. 6 hrs
3. Before application of decals 6 hrs
4. Before engine run up 30 hrs
5. Before wet tape test (adhesion test) 48 hrs
6. Before first flight 72 hrs
7. Maintenance painting
a. Complete control surface, engine intake, major skin over 9
square feet 72 hours
b. Skin panel less than 9 square feet, rivet &screw head
scratches, etc 30 hours