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Real-time measurement of organic coating performance for atmospheric galvanic corrosion protection

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The corrosion of aircraft costs the U.S. Department of Defense more than $20 billion annually and accounts for approximately 20% of all maintenance. Coatings are the most effective way to protect aircraft, but they have a finite lifetime and must be maintained or replaced before the underlying substrate is damaged by corrosion. Current aircraft maintenance practices call for coating inspections and repairs based on elapsed time and not on measurements of coating health.

Product Number: 51323-19036-SG
Author: Victoria Avance, Lindsay Davis, Brandi Clark, Fritz Friedersdorf
Publication Date: 2023
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In this laboratory work, zero resistance ammeter measurements were used to collect galvanic corrosion measurements for scribed traditional aerospace coating samples and e-coated samples in situ. The protective coating properties of traditional aerospace coatings were investigated under various environmental stressors including changes in salt loading severity and outdoor aging conditions. Both commercially available and developmental real-time galvanic corrosion monitoring devices were used to evaluate the performance of traditional aerospace coatings and e-coated and powder-coated samples in accelerated corrosion tests. Results indicated that while environment does not have an effect prior to coating damage, the initial severity once damage occurs can have a lasting effect on the galvanic corrosion rate.

In this laboratory work, zero resistance ammeter measurements were used to collect galvanic corrosion measurements for scribed traditional aerospace coating samples and e-coated samples in situ. The protective coating properties of traditional aerospace coatings were investigated under various environmental stressors including changes in salt loading severity and outdoor aging conditions. Both commercially available and developmental real-time galvanic corrosion monitoring devices were used to evaluate the performance of traditional aerospace coatings and e-coated and powder-coated samples in accelerated corrosion tests. Results indicated that while environment does not have an effect prior to coating damage, the initial severity once damage occurs can have a lasting effect on the galvanic corrosion rate.

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