Corrosion Prevention In Aerospace And Marine Electrical Systems
Corrosion continues to present a significant challenge for the aerospace industry, affecting aircraft reliability, safety and lifecycle costs. Exposure to moisture, salt-laden air, temperature extremes and airborne contaminants places constant stress on aircraft systems – particularly avionic, electrical and mechanical components where performance margins are critical. Advanced corrosion protection solutions are therefore essential to maintaining airworthiness and operational readiness.
Super CORR A has been developed specifically to address these challenges, providing long-lasting corrosion protection for sensitive aerospace systems operating in harsh environments. Originally formulated to meet demanding military requirements, the product is now widely used across aerospace and defence applications where failure is not an option.
Aerospace and Marine Corrosion Prevention Strategies
Electrical corrosion costs both private and public sectors hundreds of billions a year in repaired or replaced electrical, electronic and avionic components, but there are cost-effective, proven ways to prevent it that should sit at the heart of any preventative maintenance programme.
Electronic and electrical equipment used in adverse environments is regularly exposed to corrosive gases, causing rapid deterioration of connectors, switches and control components. The risk is particularly acute wherever close-tolerance or dissimilar-metal components are in contact, which is common in plated, anodised and galvanised assemblies – where localised galvanic corrosion can accelerate failure long after finishing is complete. Salt spray and changes in temperature and humidity present a further threat to bearings, actuators, electrical connections, high-voltage mating, switches and contactors. The failure of any of these components presents potential dangers to equipment and passengers.
Preventing corrosion involves a combination of preventive measures. An essential first step is applying a protective coating, such as SuperCORR A, which helps prevent galvanic, fretting, dissimilar-metal, intergranular, hydrogen sulphide, salt and chloride corrosion in electrical and electronic equipment, and ensures longevity and reliability wherever exposure is a concern.
Other measures include selecting resistant materials such as stainless steel or nickel alloys over carbon steel; sealing equipment in corrosion-resistant, ventilated enclosures; regular monitoring with early-warning gas detection; considering equipment design and location to reduce exposure; and having trained personnel and an emergency response plan in place should exposure occur.
SuperCORR A specialist barrier film corrosion protection
Super CORR A is a proprietary formulation supplied by EnviroTech Europe, based on approved synthetic materials, with long-lasting anti-corrosion inhibitors. It provides a superior lubrication coefficient alongside protection against moisture, wear, general and fretting corrosion, static electricity, corona and other electro-migration problems. The non-flammable film is just 7 microns (0.007mm) thick, will not harden or crack, and is formulated without sulphates, chlorides, petroleum-based material or halogens, meeting the EU RoHS directive.
Super CORR A forms an airtight seal preventing damage to electronics and other surfaces caused by exposure to fresh and saltwater moisture and corrosive gases including Sulphur dioxide (SO2), Nitrogen dioxide (NO2), Hydrogen Sulphide (H2S), Ammonia (NH3), and Chlorine (CL12) based gases, and the thermal decomposition byproduct of HFC-227ea used in fire suppression systems, Hydrogen Fluoride (HF). It is the ultimate corrosion protection formulation for aircraft, marine and a wide range of other industrial sectors. Packaged in aerosol cans, it’s easily applied by engineering crews even in difficult-to-reach locations.
HISTORY
Super CORR A was originally developed for the U.S. Air Force to comply with military specifications and to prevent electrical and electronic components from systems failures caused by corrosion. It became the industry standard for avionic corrosion protection within MROs (maintenance, repair and operations) and OEMs (overhaul and original equipment manufacturers). It’s unique ability to displace water and provide a performance enhancing level of corrosion protection has led to it being used in many other applications and industries worldwide.
INDUSTRY APPROVALS
- Approved in US Tri-service corrosion manuals and military, civilian and aircraft manufacturers, railway and transport operators worldwide.
- MIL-DTL-87177B (revised MIL-L-87177A) Type I, Grade B “Avionics Cleaning and Corrosion Prevention/Control”.
- Exceeds Mil C 81309 Corrosion Prevention Compounds.
- Approved in US Tri-Service Corrosion Manuals.
- ARMY: 1-1500-344-23.
- NAVY NAVAIR 16-1-540.
- AIRFORCE: T.O.1-1-689,691,700, 35-1-3.
- BOEING Part No. 12-371.
Extensive testing has shown it significantly reduces “no fault found” incidents: intermittent failures caused by corrosion at contact points that clear once a component is removed and re-seated.
Super CORR A has been used by the U. S. Air Force to protect the intricate workings of the F-16 Fighter Jet and by the U.S. Navy on the P 3 Orion electronic surveillance aircraft. Commercial aviation aircraft manufacturers also benefit from its use on electrical and close mechanical applications, especially on routes involving salt fog exposure or flights over open sea.
CASE STUDIES
IMAGE – Corroded PCB in aircraft control system.
Corrosion of electrical components is very prevalent problem and preventing moisture from coming in to contact with the electrical components is essential.
A leading international computer manufacturer tested Super CORR A for evaporative weight loss, a key indicator of corrosion-inhibitor and lubricant effectiveness, it recorded a weight loss of just 40% after 1,000 hours of exposure at 80°C (30% after 160 hours), the lowest of all materials tested.
IMAGE – Mild steel panels exposed to sea spray for six months showed severe rust on both an untreated section and one protected with a conventional oil-based CPC, while the section treated with Super CORR A remained visibly protected throughout.
A: Oil based CPC
B: Untreated section
C: Treated with Super CORR A demonstrating its superior performance.
Super CORR A keeps unpainted mild steel from rusting on exterior surfaces directly exposed to sea water environments for at least 6 months, protecting electrical connectors, switches, chains and drive shafts from corrosion while maintaining lubrication on moving surfaces.
CONCLUSION
Super CORR A was originally developed for the U.S. Air Force to comply with military specifications and to prevent electrical and electronic components from systems failures caused by corrosion. It became the industry standard for avionic corrosion protection within MROs (maintenance, repair and operations) and OEMs (overhaul and original equipment manufacturers). It’s unique ability to displace water and provide a performance enhancing level of corrosion protection has led to it being used in many other applications and industries worldwide.
FEATURES AND BENEFITS
- Extremely long-lasting, specially formulated and proprietary anti-corrosive inhibitor.
- Displaces both fresh and saltwater moisture.
- Prevents deterioration and contamination on all surfaces of electronic and electrical equipment and mechanical close tolerance moving components.
- Does not attract contaminants, non-reactive to most plastics.
- Eliminates premature failure of components created by moisture, general or fretting corrosion.
- Reliability increased, maintenance intervals increased, costs reduced, manufacturers save costly warranty service calls or product re-call.
- Inert compound that neither reduces nor increases electrical conductivity and will not increase or decrease contact resistance.
- Eliminates surface static electricity, corona and other electro migration problems in electronic circuit boards and connectors.
- Will not freeze or harden, retains properties even in high-altitude applications.
- Extremely resistant to air-drying and self-healing.
- Decomposition temperature of 550°F.
FURTHER INFORMATION
Please visit our website https://www.envirotech-europe.com/supercorr-a for information about other uses and applications.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
For more advice, please telephone us on +44 (0) 20 8942 9177 or use our website contact form.
All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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