Ensuring Aircraft Safety: The Importance of Corrosion Control and Material Selection

In the aviation industry, ensuring passenger safety is paramount, and a key aspect of this is reliable long-term corrosion control and monitoring. With the potential for unplanned aircraft groundings due to corrosion-related issues, establishing a robust maintenance schedule is crucial. Corrosion can compromise the structural integrity of aircraft, leading to both safety risks and operational disruptions.

When designing metallic products or structures, the initial inclination might be to choose inexpensive metals like plain carbon steel. However, it’s essential to consider the environment in which these materials will operate. Unprotected metals may not withstand the conditions they face, prompting a decision on whether to opt for protective coatings, environmental controls, or to invest in more expensive alternatives. The fluctuating prices of metals can significantly influence this decision-making process, as different materials come with varying costs tied to their purity and form.

Table 1.1 illustrates the economic implications of selecting various metals. The stark contrast in prices showcases that while steels might seem economical, the cost of using valuable metals like nickel or tin—even for protective purposes—can add significant expenses. For instance, stainless steel prices vary based on nickel content, underscoring the need for careful consideration of material selection in design processes.

Corrosion hazards can also arise from the unintentional mixing of different metals. Certain metal pairings can lead to one metal being protected while the other experiences intensified corrosion. Common examples include aluminum in contact with brass or carbon steel with stainless steel. Such combinations can lead to severe structural issues and highlight the necessity for rigorous design protocols to prevent these types of failures.

Once materials are selected, the geometry and physical design of the components must be scrutinized to minimize corrosion traps. Simple design adjustments, such as ensuring that metal surfaces spend less time in contact with water, can significantly reduce corrosion risks. Techniques like using angle sections positioned upwards, creating drainage holes, and raising tank bottoms can help mitigate issues. Furthermore, eliminating crevices is critical to prevent local oxygen depletion, which can accelerate corrosion rates.

Overall, effective corrosion management in the aviation sector requires a multifaceted approach that includes careful material selection and thoughtful design. By prioritizing these elements, the industry can enhance safety and reduce the likelihood of disruptions caused by corrosion-related failures.