Introduction to Aircraft Corrosion

Corrosion damage to aircraft fuselages is an example of atmospheric corrosion, a topic that is described in much detail in a separate module. Airports located in marine environments deserve special mention in this context. The risk and cost of corrosion damage are particularly high in aging aircraft. In the United States alone, aircraft corrosion is a multi-billion dollar problem. On some military aircraft types, corrosion maintenance hours are known to outstrip flight hours.

Corrosion manifests in many different forms. Concentration cell corrosion, or crevice corrosion, is the most common type found on airplanes, occurring whenever water is trapped between two surfaces, such as under loose paint, within a delaminated bond-line, or in an unsealed joint. It can quickly develop into pitting or exfoliation corrosion, depending on the alloy, form, and temper of the material being attacked.

Crevice corrosion damage in the lap joints of aircraft skins has become a major safety concern, particularly after the Aloha airlines incident. On April 28, 1988 a nineteen-year-old Boeing 737 aircraft, operated by Aloha airlines, lost a major portion of the upper fuselage near the front of the plane, in full flight at 24,000 feet. The Aloha incident marked a turning point in the history of aircraft corrosion. 'Click' on the picture to find out more on the Aloha incident.

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