Radiographic

X and gamma radiations, because of their unique ability to penetrate material and disclose
discontinuities, have been applied to the radiographic (x-ray) inspection of metal fabrications and
nonmetallic products.

The penetrating radiation is projected through the part to be inspected and produces an invisible
or latent image in the film. When processed, the film becomes a radiograph or shadow picture of
the object. This inspection medium and portable unit provides a fast and reliable means for
checking the integrity of airframe structures and engines. [Figure 8-21]

Eddy Current Inspection

Electromagnetic analysis is a term which describes the broad spectrum of electronic test methods
involving the intersection of magnetic fields and circulatory currents. The most widely used
technique is the eddy current. Eddy currents are composed of free electrons under the influence of
an induced electromagnetic field.

Eddy current is used in aircraft maintenance to inspect jet engine turbine shafts and vanes, wing
skins, wheels, bolt holes, and spark plug bores for cracks, heat or frame damage.

Basic Principles
When an alternating current is passed through a coil, it develops a magnetic field around the coil,
which in turn induces a voltage of opposite polarity in the coil and opposes the flow of original
current. If this coil is placed in such a way that the magnetic field passes through an electrically
conducting specimen, eddy currents will be induced into the specimen. The eddy currents create
their own field which varies the original fields opposition to the flow of original current. The
specimens susceptibility to eddy currents determines the current flow through the coil.
Corrosion Control
Many aircraft structures are made of metal, and the most insidious form of damage to those
structures is corrosion. From the moment the metal is manufactured, it must be protected from the
deleterious effects of the environment that surrounds it.

Note: FAA Advisory Circular (AC) 43-4A, Corrosion Control for Aircraft.

Metal corrosion is the deterioration of the metal by chemical or electrochemical attack. This type
of damage can take place internally as well as on the surface.

Types of Corrosion
Two general classifications of corrosion
1. Direct chemical attack - or pure chemical corrosion is an attack resulting from a direct
exposure of a bare surface to caustic liquid or gaseous agents.
2. Electrochemical attack- an electrochemical attack may be likened chemically to the electrolytic
reaction that takes place in electroplating, anodizing, or in a dry cell battery. The reaction in this
corrosive attack requires a medium, usually water, which is capable of conducting a tiny current
of electricity.

In both types of corrosion, the metal is converted into a metallic compound such as an oxide,
hydroxide, or sulfate.

The corrosion process always involves two simultaneous changes: The metal that is attacked or
oxidized suffers what may be called anodic change, and the corrosive agent is reduced and may
be considered as undergoing cathodic change.

Forms of Corrosion

Surface Corrosion
Surface corrosion appears as a general roughening, etching, or pitting of the surface of a metal,
frequently accompanied by a powdery deposit of corrosion products.
Surface corrosion may be caused by either direct chemical or electrochemical attack. Sometimes
corrosion will spread under the surface coating and cannot be recognized by either the roughening
of the surface or the powdery deposit. Instead, closer inspection will reveal the paint or plating is
lifted off the surface in small blisters which result from the pressure of the underlying
accumulation of corrosion products. [Figure 6-5]
Filiform corrosion gives the appearance of a series of small worms under the paint surface. It is
often seen on surfaces that have been improperly chemically treated prior to painting. [Figure 6-
6]

Dissimilar Metal Corrosion

Extensive pitting damage may result from contact between dissimilar metal parts in the presence
of a conductor. While surface corrosion may or may not be taking place, a galvanic action, not
unlike electroplating, occurs at the points or areas of contact where the insulation between the
surfaces has broken down or been omitted. This electrochemical attack can be very serious
because in many instances the action is taking place out of sight, and the only way to detect it
prior to structural failure is by disassembly and inspection. [Figure 6-7]

Figure 6-7. Dissimilar metal corrosion.

Intergranular Corrosion

This type of corrosion is an attack along the grain boundaries of an alloy and commonly results
from a lack of uniformity in the alloy structure. Aluminum alloys and some stainless steels are
particularly susceptible to this form of electrochemical attack.
Stress Corrosion
Stress corrosion occurs as the result of the combined effect of sustained tensile stresses and a
corrosive environment. Stress corrosion cracking is found in most metal systems; however, it is
particularly characteristic of aluminum, copper, certain stainless steels, and high strength alloy
steels (over 240,000 psi). It usually occurs along lines of cold working and may be transgranular
or intergranular in nature. Aluminum alloy bellcranks with pressed in bushings, landing gear
shock struts with pipe thread type grease fittings.

Fretting Corrosion
Fretting corrosion is a particularly damaging form of corrosive attack that occurs when two
mating surfaces, normally at rest with respect to one another, are subject to slight relative motion.

Cathode:
A negatively charged electrode, as of an electrolytic cell, a storage battery, or an electron
tube.
Anode:
A positively charged electrode, as of an electrolytic cell, storage battery, or electron tube.

CORROSION CONTROL

CADMIUM AND ZINC-PLATED PARTS

Cadmium plating is used extensively in aircraft construction as a protective finish over

both steel and copper alloys. Protection is provided by a sacrificial process in which the
cadmium is attacked rather than the underlying base material. Properly functioning
cadmium surface coatings may show mottling, ranging from white to brown to black
spots on their surfaces. These show the sacrificial protection being offered by the
cadmium coat, and under no condition should such spotting be removed merely for
appearance sake.
METAL SPRAYING
Metal is melted and sprayed on the surface to be protected. The surface must be properly
prepared and thoroughly cleaned to prevent peeling of the sprayed coat.