If you have an airplane to maintain, you have a corrosion control problem. But knowing you have a problem is the easy part. Once you find it, the question is what do you do about it? Or if you don’t find it today, how do you minimize the chances that it will be there tomorrow? Today, there is a huge list of corrosion inhibiting compounds (CICs), corrosion

prevention compounds (CPCs), tools, tapes, cleaners, and barriers to choose from. At times it can be overwhelming. To help you get a head start on your corrosion combat efforts, Aviation Maintenance has compiled the following list of some of the latest corrosion control and prevention products.

 

Conductive Antenna Gaskets Ease Inspections

Leakage around antenna gaskets is a typical corrosion cause. Av-DEC’s HiTak Conductive Antenna Gasket is a one-step solution that eliminates moisture intrusion around antennas and reduces antenna removal and inspection times. "The recurring problem of antenna/fuselage corrosion is something one of our customers was battling, so we developed the product to help them solve the problem," explained Lane Smith, co-founder of Av-DEC. "It’s a die-cut polyurethane gasket that has an embedded aluminum mesh that provides a moisture barrier and excellent metal-to-metal conductivity."

HiTak gaskets are a compression-type product that create a vapor-tight seal indefinitely and will not harden or dry out even under extreme temperature variations. HiTak also eliminates the need for a technician to laboriously remove and then reapply the polysulfide-type materials used as fillet seals on most antennas. The adhesive gasket is pre-cured so the technician handles no chemicals.�

Another new product is Av-DEC’s HiTak Tape. "Developed for use in the airframe, HiTak Tape is applied wherever metal-to-metal surfaces meet," explained, Jeff Busby, Av-DEC’s other founding partner. "It is applied like any tape, and when the fasteners are pushed through and tightened it creates a compression seal. And because it conforms to irregular shapes it is ideal for application to surfaces where liquid ingress is a problem like under galleys, door seals, floorboards, and stringers." Av-DEC products are distributed by Aviall (www.aviall.com)

Av-DEC
Phone: 817-738-9161
Web: www.avdec.com

 

Tape Seals

W.L. Gore’s SKYFLEX tape sealant helps prevent corrosion and fluid leakage by sealing fuselage and wing panels, access doors, windshields, floorboards, antennae, and fuel panels. SKYFLEX is made of 100 percent PTFE, which is chemically inert to all common chemicals, according to the company, and it works at temperatures ranging from —240 to +260 degrees centrigrade. SKYFLEX tape sealant can be reused many times and it is weather- and ultraviolet-resistant. W.L. Gore also manufactures conductive antenna gaskets featuring a reusable, flexible gasket material surrounding a conductive center material that provides excellent grounding to the airframe.

W.L. Gore
Phone: 800-445-4673 or 302-292-5100
Web: www.gore.com/electronics

 

Odorless CPC Remover

While everyone concentrates on products or chemicals to apply to control corrosion, it can be just as important to be able to properly remove CICs and CPCs when necessary. To make that job more efficient, Chemetall Oakite (formerly Dinol, U.S.A.) introduced a product called Ardrox 5410. One of the big advantages of 5410 is that it is odor neutral. "A few years ago they started using citrus-based solvents in a lot of cleaners," explained Mike Lissandrello, product manager, Chemetall Oakite. "That orange smell can overwhelm you when you had to use a lot of it in a confined area. With Ardrox 5410 you won’t have that problem, which makes it great for use while the airplane is in the hangar."

Ardrox 5410 is a clear liquid cleaner that meets the sandwich corrosion, paint softening, crazing, and hydrogen embrittlement requirements of Boeing specification D6-17487. "It does a really good job of removing general dirt and aged or contaminated CICs and CPCs on the airframe," he said. "It is bio-degradable, making it environmentally and technician friendly." And because it can be removed with rags, there is no need to introduce wash water into the airframe; after all, the goal of corrosion control is to keep water out of these areas.

Chemetall Oakite
Phone: 800-331-4304 or 206-618-8878
Web: www.aerospace.chemetall.com

 

New and Improved Anti-Corrosion/Lubrication

"We are just about ready to introduce a new and improved version of our popular ACF-50 anti-corrosion/lubricating compound," said Mark Pearson, Lear Chemical’s acting general manager. "We’ve been experimenting with new variations for about four years, but just about a year ago we found one that provides product improvements across the board."

Pearson said the company is in the final stages of field-testing the new product and plans are to have it on the market by year end. "It’s tough to make a proven product like ACF-50 better," he added. "But our tests so far are proving that we’ve been successful at creating something that will meet our customers’ changing needs."

Until then, technicians will still be able to rely on the same corrosion inhibiting performance that they have enjoyed for nearly 20-years: ACF-50’s ability to actively penetrate into seams, lap joints, and beneath rivet heads to repel moisture and stop corrosion and leave behind a clean, clear, ultra-thin fluid compound that protects metal surfaces for up to 24-months.

Lear Chemical
Phone: 800-256-2548 or 905-564-0018
Web: www.learchem.com

 

CPC for Avionics and Electronics Connectors

As avionics become more integrated into every system on modern aircraft, technicians are faced with the growing challenges of controlling corrosion in and around electronics connectors. Lektro-Tech’s SUPER CORR-B is formulated to prevent deterioration, contamination, and wear on all surfaces of connectors for electrical and avionics equipment, as well as other close-tolerance components.�

The company stated that the U.S. Navy and Air Force use SUPER CORR-B and it exceeds Mil Spec L-87177A. Walter Flocken, Lektro-Tech’s director of marketing, said the product contains specially formulated, proprietary corrosion inhibitors and lubricants that protect critical electronics connectors and components against moisture, general and fretting corrosion, surface static electricity, corona, and other electro-migration problems.

Flocken also said that SUPER CORR-B is currently under analysis by airframe and avionics/electronics manufacturers and so far it is proving to be just as effective in commercial situations as it has been for the military. The company says that by applying SUPER CORR-B as a preventative measure operators "will eliminate premature failure of the component caused by moisture and general or fretting corrosion, making the component more reliable to the end user and saving the manufacturer costly warranty calls."

Lektro-Tech
Phone: 877-881-3737 or 813-254-1380
Web: www.lektrotech.com

 

Fast-Drying, Long-Lasting CPCs

Socomor’s latest corrosion inhibiting compound product was developed in response to a request from Airbus to create a highly-penetrating, long-lasting, fast-drying CIC. Socomor’s answer to this challenge was the introduction of SOCOPAC 65H CIC. According to the company, SOCOPAC 65H is the first CIC that is not only fully compliant, but it meets and/or exceeds all aeronautical specifications from Boeing, Airbus, Snecma, Bombardier, and U.S. Mil Spec C-16173 D.

Socomor also stated that the unique formulation of the SOCOPAC 65H CIC creates not only a product that offers extremely fast drying times, it also effectively provides long-term corrosion inhibiting and efficient penetrating/water repellent characteristics. So, once it’s on, it protects for a long time.

The resulting lightweight, hard thin film forms an efficient barrier against moisture, oxygen, and other corrosives and can be applied on painted and unpainted metals. Because of its durability, the company stated that it has proven to be effective in controlling corrosion in landing gear, wheel wells, box sections, load bays, under floors, and in door surrounds.

Socomor
Phone: 33 (0) 2 9743 7690
Web: www.socomor.com

 

Polyurethane Moisture Barrier Tapes

3M Aerospace has developed a new family of products that could forever change corrosion control under and around galleys, lavatories, and entryways. When applied to floorboards and subassemblies, 3M’s polyurethane protective tapes create an effective moisture-resistant barrier. These non-hazardous, easy to apply products significantly reduce floor system corrosion damage and ongoing maintenance requirements.

According to the company, the thin, flexible, highly adhesive tapes easily conform to the edge of the floor/vertical panel intersection to prevent fluid migration into these critical areas and subsystems. And it’s easy to apply: run it off a roll—just like a piece of Scotch Tape—and apply it to the underlying areas. 3M offers the products in a variety of widths to minimize application times. The company also stated that the products are specified by commercial OEMs, "to resolve performance problems of other products."

Another 3M product you’ll probably want to add to your corrosion control toolbox is the non-abrasive Radial Bristle Discs. These new products not only cut the time it takes to remove paint and corrosion build-up—one major U.S. government client stated it cut its labor costs by up to 50 percent—the flexible bristles conform to the part’s shape, allowing for a more uniform finish without damaging the base surface. "Aircraft maintenance technicians now have products that are safer to use, significantly reduce the time required to complete the job, and provide enhanced results," said Larry Ptasienski, MRO market segment manager, 3M Aerospace & Aircraft Maintenance Department.

3M Aerospace (protective tapes)
Phone: 800-362-3550
3M Aerospace (Bristle Discs/
Phone: 866-279-1235
Web: www.3M.com

 

High-Penetration CICs and CPCs

The major problem most technicians face when battling corrosion is that you usually can’t see the areas that it’s attacking until it has done its damage. That’s why highly penetrating products are important. "The star of our show right now is our Cor-Ban 35," explained Jason Smith, R&D laboratory manager for Zip-Chem Products. "It was chosen by Boeing based on its corrosion protection and great penetration properties. In fact, it was named after the Boeing specification BMA 3-35." The company states that along with Boeing, Cor-Ban 35 is also approved by Airbus, Sikorsky, other OEMs, and the U.S. military.

Smith explained that Cor-Ban 35’s wicking properties allow it to quickly and effectively migrate into tiny spaces between metal panels such as lap joints, beams, or struts. The product wicks in and pushes offending moisture out, effectively stopping corrosion.

"Applied properly, it will last for several years under normal situations," Smith said. "But it is a temporary protective coating so in some applications it will need periodic maintenance —touching-up in corrosive areas like wheel wells, under lavatories, or in areas that are subject to the application of various cleaners." The hard surface, high-solids film is clear to allow visual inspection of the base metal.

Zip-Chem
Phone: 800-648-2661 or 408-729-0291
Web: www.zipchem.com

 

Polymer Paint Coating

While most corrosion inhibitors are designed to work inside the airframe, technicians know that keeping dirt and exhaust build-up off an aircraft’s exterior can be an effective way to help stop corrosion before it starts. Unfortunately, that also requires a lot of extra work. Now, however, there’s an easy way, RejeX by� Corrosion Technologies. RejeX is a polymer coating that seals painted surfaces against stains, oil, grease, tar, and bug acids. When applied to areas around exhaust outlets, stains wash right off with mild detergent and water.

Jim Val Gilder, president of Corrosion Technologies, said that a turbine aircraft customer� said they had previously spent two hours cleaning exhaust stains off the airframe after every flight. But with RejeX, that time had been cut to only 15 minutes.

How does it work? RejeX creates a slick, long-lasting, glass-like barrier that prevents the build up of dirt and other corrosive materials on painted surfaces. You apply it just like automotive wax. Wipe it on. Let it cure to a light haze and buff it off. And because it contains no abrasives, RejeX will not harm painted surfaces. In fact, it is recommended for use on plastic windshields. And when you use RejeX on the airframe, there’s no need to use another wax or polish because RejeX leaves a solid shine.

Corrosion Technologies is also the manufacturer of the popular CorrosionX anti-corrosion treatment system.

Corrosion Technologies
Phone: 800-638-7361 or 972-271-7361
Web: www.corrosionx.com