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C.P.C.I.C.F.
Information on:
CORROSION PREVENTION
CORROSION INSPECTION
CORROSION FINDINGS
RECORD OF REVISION
INSERTION INSERTION
REV ISSUE BY REV ISSUE BY
DATE DATE
0 MAR 92
1 JULY 96
2 MAY 2000
3 FEB 2005
4 DEC 2014
RECORD OF REVISION
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HIGHLIGHTS
REVISION N°04 DATED DEC. 2014
Pages which have been added, revised or deleted are outlined below together with the highlight of the revision.
HIGHLIGHTS
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HIGHLIGHTS
REVISION N°04 DATED DEC. 2014
HIGHLIGHTS
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N, R or D indicates respectively pages which are New, Revised or Deleted. Remove and insert the affected pages and complete the Record of Revisions and the
Record of Temporary Revision as necessary.
N, R or D indicates respectively pages which are New, Revised or Deleted. Remove and insert the affected pages and complete the Record of Revisions and the
Record of Temporary Revision as necessary.
N, R or D indicates respectively pages which are New, Revised or Deleted. Remove and insert the affected pages and complete the Record of Revisions and the
Record of Temporary Revision as necessary.
N, R or D indicates respectively pages which are New, Revised or Deleted. Remove and insert the affected pages and complete the Record of Revisions and the
Record of Temporary Revision as necessary.
N, R or D indicates respectively pages which are New, Revised or Deleted. Remove and insert the affected pages and complete the Record of Revisions and the
Record of Temporary Revision as necessary.
N, R or D indicates respectively pages which are New, Revised or Deleted. Remove and insert the affected pages and complete the Record of Revisions and the
Record of Temporary Revision as necessary.
0 - SUMMARY
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0. SUMMARY
0. SUMMARY 9. BONDING
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0. SUMMARY
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1 - PURPOSE
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1. PURPOSE
This document is intended to provide ATR operators with general The FAA AC 43-4A has been a valuable source of information for the
information on corrosion, with reminders of requirements, instructions and redaction of this Document and Air Carriers are advised to take full
engineering data included in the ATR Technical Publications and with notes knowledge of its content.
of the in-service corrosion findings and of subsequent undertaken actions.
This was made in an attempt to assist Air Carriers in easily finding out the Certain information presented in this document, such as:
relevant data necessary to develop and implement their maintenance
program for corrosion and to take appropriate preventive and curative • Instructions for removal of corrosion,
actions when necessary. • Baseline Maintenance Program requirements,
• General procedures for inspections,
A maintenance program for corrosion is required to prevent corrosion that
may jeopardize the continued airworthiness of the aircraft. are extracted, in part or in totality, from ATR Technical Publications,
especially from:
The ATR MRB Document which represents the baseline maintenance • Structural Repair Manual,
program has been established during the MSG-3 analysis process upon • MRB Document,
mean environment and use conditions and is assumed as the optimum
provisional maintenance program to meet the regulation and the needs of • Maintenance Manual.
the typical operator.
It is made clear that operators shall refer to the applicable sections of these
Systematic corrosion damage in the fleet will result in a modification of the Publications as the sole relevant data, while this document is of an advisory
MRBD and MPD requirements, initiated by ATR. nature.
Operators remain responsible, under the surveillance of their respective The operator is strongly recommended to provide information to ATR
competent Authorities, to adapt their maintenance program to non-typical
STRUCTURE ENGINEERING SUPPORT for any corrosion findings
conditions, as far as corrosion is concerned, taking into account their
using the "Corrosion Inspection Report" form on page 2.6.
corrosion findings during successive scheduled inspections.
FAX : + 33 (0) 5 62 21 62 90
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1. PURPOSE
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2. GENERALITY
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2. GENERALITY
INDEX
2.1. INTRODUCTION
2.6. RECOMMENDATIONS
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2. GENERALITY
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2. GENERALITY
A finding of Level 2 corrosion requires repair, reinforcement or complete 2.3. CORROSION PRONE AREA
or partial replacement of the applicable structure.
Some areas of the aircraft are prone to corrosion due to the particular
structural detail, to dissimilar metal, build-up of moisture, engine exhaust
Level 3 corrosion is:
gas deposit, accumulation of water, debris, loose fasteners, hydraulic
Corrosion occurring during the first or subsequent accomplishments of a fluids, ineffective drain holes plugged by dirt, grease, abrasion, etc.
corrosion inspection task that the operator determines to be an urgent
airworthiness concern. The main areas prone to corrosion are:
These areas should be checked for corrosion whenever possible and the
causes that favour corrosion eliminated (water accumulation, spillage of
any kind, dirt, plugged drain holes, etc.).
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2. GENERALITY
Mild and moderate corrosion not exceeding the allowable damage limits Eddy current (primarily low frequency) can be used to detect thinning due
(see the SRM appropriate chapters) must be treated as per SRM Chapter to corrosion and cracks in multilayered structure. Low frequency eddy
51-21-42. current can be used to detect corrosion in underlying structure because the
Eddy current will penetrate in the second layer with sufficient sensitivity
NOTE: TO AVOID THE CORROSION TO RE-OCCUR, IT IS for approximate results.
ESSENTIAL TO PERFORM A COMPLETE
DECONTAMINATION OF THE AFFECTED PARTS X-RAY inspection.
PRIOR TO APPLY ANY REPAIR INSTRUCTION.
The X-RAY technique is effective for severe or moderate-to severe
Severe or moderate corrosion out of allowable limits requires the corrosion but its use is limited for mild-to-moderate corrosion. In any case
application of approved repair data or replacement of the affected parts. X-RAY requires qualified and certified personnel to obtain reliable
results.
During successive inspections requiring rework / blend-out, the possibility
to reach the allowable limits must be checked (previous material removal
Ultrasonic inspection
must be accounted for).
2.5. CORROSION INSPECTION AND MEASUREMENT Ultrasonic inspection provides sensitive detection capability for corrosion
damage detection when access is available to a surface with a continuous
bulk of material exposed to corrosion. Ultrasonic inspection is commonly
The extent and the depth of any corrosion must be clearly identified. used to detect exfoliation, stress corrosion cracks and general thinning of
material.
The visual inspection is the most common means to detect corrosion.
If the visual inspection is deemed not effective (hidden corrosion Trained personnel must conduct the examination if any useful information
suspected) adequate inspection technique or disassembling shall be has to be derived from indicating devices.
performed.
The most common means of inspection, other than visual inspection, to Use of calibration block may be required.
detect corrosion are:
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2. GENERALITY
2.6. RECOMMENDATIONS
For each zone of the aircraft the following recommendations are given
when performing inspection:
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3. CORROSION PREVENTION AND CONTROL PROGRAM APPLICATION
The following instructions are applicable to each zone of ATR42 and • Request for extension of the threshold/repeat interval of inspection of
ATR72 aircraft: the aircraft can be submitted to Regulatory Agency (NAA) of each
operator if corrosion findings are at NO CORROSION between
• Baseline Maintenance Programs are given in MRB/MPD of ATR42
successive inspections.
and ATR72 and were developed for aircraft operating in average
environmental conditions and therefore shall be considered as the • The Corrosion Prevention and Control Program is considered effective
optimum provisional Programs for typical operators. if the corrosion findings during successive inspections are MILD
CORROSION or NO CORROSION.
• Any change to the Baseline Maintenance Programs is subjected to
approval of the (Regulatory Agency) National Airworthiness Authority • If the corrosion findings are MODERATE CORROSION, the
(NAA) of each operator. Corrosion Prevention and Control Program is considered not
effective. Adjustment (decrease of the threshold/interval of
• Threshold of inspection starts at the aircraft FIRST FLIGHT. Repeat
inspections), based on the specific experience, shall be made to
interval of inspection starts at the time the last inspection was
the Program to maintain the corrosion findings during successive
performed.
inspections at MILD CORROSION or NO CORROSION.
• Operators having an existing Corrosion Prevention and Control Program
• If the corrosion findings are SEVERE CORROSION, immediate
may continue with their existing Program if proven effective and if the
actions to define the causes of such corrosion shall be
objective of this document are met.
implemented, inspection extended to the rest of the fleet shall
• Operators without Corrosion Prevention and Control Program be performed and adjustment to the Corrosion Prevention and
shall implement the Baseline Maintenance Program. Control Program may be made to bring the level of corrosion
between successive inspections at MILD CORROSION or NO
When applying the Baseline Program, pay special attention to
CORROSION.
the operating environment or corrosive cargo loading.
• Depending of the corrosion occurrence related to the
• Individual operators having similar operating environment may group
environment and operational severity conditions, the frequency
together for the application of the Corrosion Prevention and Control
of the inspections given in the Baseline Maintenance Program
Program.
shall be adjusted on the base of the operator specific experience.
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3. CORROSION PREVENTION AND CONTROL PROGRAM APPLICATION
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4 – TYPE OF CORROSION
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4. TYPE OF CORROSION
CREVI CE
SYMPTOMS:
Severe local corrosion along faying surface.
CAUSE:
Penetration of oxygen and corrosive agent into a joint.
PREVENTION:
Efficient sealing of faying surfaces from corrosive
substances.
Dissimilar metal
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4. TYPE OF CORROSION
FRETTI NG
SYMPTOMS:
Destruction of natural protective film over large surfaces and loss
of metal from surface followed by dark coloured oxidation.
CAUSE:
Abrasion of metal under load in humid environmental conditions.
PREVENTION:
Detail design and protective treatment, material selection.
Al alloy
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4. TYPE OF CORROSION
GALVANI C
SYMPTOMS:
Powder-like white or grey deposits.
CAUSE:
Two dissimilar metals in contact.
PREVENTION:
Detail design, protective treatment, special assembly
techniques. (Sealing, electrical insulation of metals).
Al alloy Moisture
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4. TYPE OF CORROSION
PI TTI NG
SYMPTOMS:
Holes in metal surface.
CAUSE:
Halogen ions present in attacking electrolyte
(corrosive agent), destroying surface treatment.
PREVENTION:
Protective treatment.
Al alloy
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4. TYPE OF CORROSION
I NTERGRANULAR
SYMPTOMS:
Normally only perceived by cracking.
CAUSE:
Chemical action along grain boundaries within the material
Difference in electrical potential between grain and grain
boundaries.
PREVENTION:
Material selection and protective treatment.
Clad Moisture
Al alloy
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4. TYPE OF CORROSION
EXFOLI ATI ON
SYMPTOMS:
Flaking and loss of metal thickness.
CAUSE:
Swelling and flaking at grain ends exposed by machining.
PREVENTION:
Pre-heat treatment and material selection.
Al alloy Moisture
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4. TYPE OF CORROSION
FI LI FORM
SYMPTOMS:
Paint bulging and longitudinal propagation of blisters
on surface.
CAUSE:
Paint damage.
PREVENTION:
Corrosion resistant primer,
restoration of paint system.
Al alloy
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4. TYPE OF CORROSION
SYMPTOMS:
Local surface attack or formation of deposits such as fungi.
CAUSE:
Growth of micro-organisms in moisture traps.
PREVENTION:
Detail design, protective treatment and assembly
techniques, use of inhibitors in primers, etc.
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4. TYPE OF CORROSION
STRESS
SYMPTOMS:
Normally only perceived by cracking with fast crack
propagation leaving bare metal subject to corrosion.
CAUSE:
Residual stress from manufacturing process or stress
concentrations due to design features.
PREVENTION:
Material selection and handing care, detail design and
assembly techniques, background surface protection.
Primer Moisture
Al alloy
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4. TYPE OF CORROSION
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5. REMOVAL OF CORROSION
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5. REMOVAL OF CORROSION
INDEX
5.1. GENERAL
General relevant instructions for removal of corrosion are given in the ATR SRM Chapters 51-21-42 and 51-21-58.
The following is repeated as a reminder.
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5. REMOVAL OF CORROSION
A. All structural components which are affected by corrosion are to be A. Equipment and Materials
treated immediately.
• Scraper.
B. Trained personnel must determine the extent of corrosion and compare • Cutter or hand polisher.
with permissible corrosion damage limits (Ref. Chapters 52 to 57) of • Non-metallic abrasive pads (e.g. Scotchbrite very fine grade).
SRM before corrosion removal and treatment operations can begin. • Nylon brush.
• Chlorinated or ketonic solvent (Methyl-ethyl-ketone, baltane).
C. It is very important that all corrosion deposits are completely removed • Demineralized water.
before repairing corrosion damage. Minor residues can act as starting • Paint stripper.
points for new corrosion. The repaired area must be checked to ensure • Magnifying glass, 5-10x.
complete removal of corrosion to avoid the possibility of crack • Flash light.
propagation. • Inspection mirror.
• Protective goggles.
D. All areas, where corrosion has to be treated, must be cleaned from oil,
• Protective gloves.
grease, dirt, and paint.
• Dye penetrant.
• Eddy current equipment.
B. Preparation
For decontamination:
• Chromic acid anhydride solution
CRO3: 90 g/l
Demineralized water
For neutralization:
• Potassium dichromate solution
K2 CR2 O7: 33 g/l
Demineralized water
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5. REMOVAL OF CORROSION
• Masking of non-corroded adjacent areas by installing plastic screens (a) Mechanical action (See SRM Chapter 51-21-58)
secured with adhesive tape.
Use of steel wire brushes is prohibited.
• Cle aning and degreasing with cotton cloth moistened in
solvent. • Rub down using scotchbrite pads or emery cloth. Grade
selection will depend on corrosion extent. Finish off using the
• Paint stripping: finest grade.
- Chemical stripping (external areas, isolated parts, areas with • For extensive corrosion use nylon brushes (recommended),
fixed boundaries). cutters, grinding wheels.
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5. REMOVAL OF CORROSION
• Remove dust and degrease with solvent. Overall rinsing with demineralized water and drying off with dry oil-
• Using a brush, apply chromic acid anhydride solution (chromic free air.
acid (10%) + demineralized water) to the damaged area.
• Allow solution to act for 10 mn. (6) Paint touch-up
• Rinse off with demineralized water and rub down with a nylon
brush to eliminate dark yellow coloration. The time elapsed between the drying phase and paint application
• Wipe off with cloth. shall be as short as possible.
Dry off with dry oil-free air. If this operation is delayed, the area treated against corrosion shall be
protected to prevent any external contamination.
NOTE: If rinsing cannot be performed correctly and in cases
where the chromic acid anhydride solution may reach • Perform paint touch-up as follows:
inaccessible structural stackings, do not apply
chemical action. - Wash primer P99 or A 166 ASTRAL/SIKKENS.
(3) Checking of corrosion removal NOTE: Wash primer can be replaced by application of
Alodine 1200.
Using a magnifying glass, check for evidence of corrosion and In this case, after Alodine application rinse off with clear
for presence of cracks. water (do not rub) and dry off with dry oil-free air.
In doubt, conduct dye -pene trant or Eddy-current inspection.
• Apply protective finish scheme relevant to the zone:
(4) Neutralization
- primer,
• Apply potassium dichromate solution (3% + demineralized - top coat,
water) with brush. - livery.
• Allow solution to act until surface is dry.
• Rinse off with demineralized water and rub down with a nylon
brush to eliminate yellow traces.
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5. REMOVAL OF CORROSION
Accomplishment of this process is applicable to steel types having the (1) Surface preparation
following characteristics:
• Masking of non-corroded adjacent areas by installation of plastic
• Low-alloy steels with main added element < 5% and total alloy elements screens secured with adhesive tape.
< 10%. • Mechanical removal of corrosion by rubbing with scotchbrite and
• Bare metal condition (no cadmium plating, no chop process). abrasive pads. (Ref. SRM 51-21-58).
• Tensile strength < 130 hb or 1300 MPa.
(2) Deoxidation
A. Equipment and materials
• Remove dust and clean with solvent.
• Non-metallic pad (scotchbrite very fine grade). • Brush apply either DERCAM or ARDROX Type 140 (these two
• Abrasive paper (fine 400 grade). products are ready for use) and rub well into surface using
• Deoxidizing agents (equivalent products): scotchbrite pad.
- Rust removing phosphating agent DERCAM If part is removable, immerse it in the deoxidizing solution.
SARL DERCAM • Allow to act for 30 min. and repeat application.
24, Chemin du Plat
69130 ECULLY
Tel.: 78.33.10.53 IMPORTANT NOTE:
- ARDROX 11 Type 140 Within one hour, the action of the product causes an
ARDROX SA attenuation of the corrosion but the attack is not sufficient to
41, rue des Francs Bourgeois reach the uncorroded metal substrate.
75004 PARIS
Tel.: 38.87.70.00 Several hours are then necessary to obtain complete
neutralization of corrosion products and superficial
- Chlorinated or ketonic solvent (MEK, baltane). phosphating of metal (white or greyish film).
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5. REMOVAL OF CORROSION
• Using suitable light source, make certain that all areas have been
treated.
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6. CORROSION SEVERITY MAP
ANCHORAGE
SEATTLE
MONTREAL
MODERATE
HOUSTON
SEVERE MIAMI
HAVANA
HAITI PUERTO
CUBA RICO
MEXICO ST.
JAMAICA
DOMINGO
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6. CORROSION SEVERITY MAP
BOGOTA
BELEM
GUAYAQUIL
FORTALEZA
PACIFIC OCEAN
RECIFE
LIMA
BRASILIA SALVADOR
LA PAZ
SAO PAULO
RIO DE JANEIRO
ASUNCION
MILD SANTIAGO
BUENOS MONTEVIDEO
MODERATE AIRES
SEVERE
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6. CORROSION SEVERITY MAP
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6. CORROSION SEVERITY MAP
6.4. EUROPE
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6. CORROSION SEVERITY MAP
6.5. AFRICA
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6. CORROSION SEVERITY MAP
6.6. ASIA
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6. CORROSION SEVERITY MAP
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7. MATERIAL SELECTION
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7. MATERIAL SELECTION
In order to reach the life objectives of 25 years for the structure, particular
attention has been paid to corrosion preventive measures from the earliest
design stage.
Aluminum alloys (2024 and 7075) are generally used on ATR, with
different heat treatment.
The 7000 series aluminum alloys used on the ATR are heat treated to
produce either T6, T73 or T76 tempers.
T73 has excellent stress corrosion and exfoliation corrosion resistance. T76
temper has strength between T73 and T6, with high exfoliation corrosion
resistance and intermediate stress corrosion resistance.
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7. MATERIAL SELECTION
T3 T42 T351 T3511 T6 T651 T6511 T7651 T7651 T74 T73 T7351
1
*"W" condition = unstable condition directly after solution heat treatment (and quenching)
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7. MATERIAL SELECTION
FASTENERS INSTALLATION
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7. MATERIAL SELECTION
FRAME SPLICING
TYPICAL FRAME 1 2
3
4
5
FRAME SIDE LOBE
6
Material = 7075 clad
FRAME CROWN LOBE Treatment = T6
7
Material = 7075 clad
Treatment = T6
8
10
11
14
15
16 FLOOR BEAM
17 Material = 7075
18
20 19 Treatment = T6
21 STANCHION
Material = 7075
Treatment = T6511
FRAME LOWER LOBE Page 7.4
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Treatment = T6
C.P.C.I.C.F.
7. MATERIAL SELECTION
STRAP SKIN
FWD
FR 29 RIVETS
STRINGER
Material = 7075 clad
Treatment = T6
− Interposition of polysulphide type B (PR 1776 B - PR 1431 G TYPE • Bonded assemblies: filling of cavities with polysulphide type A.
I, II, III, IV - PR 1422 B2- PR 1440 B - PR 1826 B).
− Filling of cavities with polysulphide type A. • Welded assemblies: seal beads with polysulphide type B.
− Seal beads with polysulphide type B.
− Overlay of fasteners and seal beads with polysulphide type A* • Scarcely removable assemblies: seal beads with type B polysulphide
(PR 1776 A- PR 1422 A). (PR1773B) .
• Removable panels: • Frequently removable assemblies: seal beads with type B polysulphide
(PR1773B), with partial interposition of demoulding chemical agent
Interposition of polysulphide type B (PR 1403 GB - PR 1773 A/B) with (QZ-5111).
partial interposition of demoulding agent.
• Aerodynamic finishing: seal beads with polysulphide type B.
• Piano junction recesses:
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