Prognostic investigation of galvanic corrosion precursors in aircraft structures and their detection strategy

Robin James, Tae Hee Kim, Ram Mohan Narayanan

Research output: Chapter in Book/Report/Conference proceedingConference contribution

3 Citations (Scopus)

Abstract

Aluminum alloys have been the dominant materials for aerospace construction in the past fifty years due to their light weight, forming and alloying, and relative low cost in comparison to titanium and composites. However, in recent years, carbon fiber reinforced polymers (CFRPs) and honeycomb materials have been used in aircrafts in the quest to attain lower weight, high temperature resistance, and better fuel efficiency. When these two materials are coupled together, the structural strength of the aircraft is unparalleled, but this comes at a price, namely galvanic corrosion. Previous experimental results have shown that when CFRP composite materials are joined with high strength aluminum alloys (AA7075-T6 or AA2024-T3), galvanic corrosion occurs at the material interfaces, and the aluminum is in greater danger of corroding, particularly since carbon and aluminum are on the opposite ends of the galvanic series. In this paper, we explore the occurrence of the recognizable precursors of galvanic corrosion when CFRP plate is coupled to an aluminum alloy using SS-304 bolts and exposed to environmental degradation, which creates significant concerns for aircraft structural reliability. The galvanic corrosion software package, BEASY, is used to simulate the growth of corrosion in the designed specimen after which a microwave non-destructive testing (NDT) technique is explored to detect corrosion defects that appear at the interface of this galvanic couple. This paper also explores a loaded waveguide technique to determine the dielectric constant of the final corrosion product at the Q-band millimeter-wave frequency range (33-50 GHz), as this can be an invaluable asset in developing early detection strategies.

Original languageEnglish (US)
Title of host publicationNondestructive Characterization and Monitoring of Advanced Materials, Aerospace, and Civil Infrastructure 2017
EditorsTzu-Yang Yu, H. Felix Wu, Peter J. Shull, Andrew L. Gyekenyesi
PublisherSPIE
ISBN (Electronic)9781510608238
DOIs
StatePublished - Jan 1 2017
EventConference on Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XI 2017 - Portland, United States
Duration: Mar 26 2017Mar 29 2017

Publication series

NameProceedings of SPIE - The International Society for Optical Engineering
Volume10169
ISSN (Print)0277-786X
ISSN (Electronic)1996-756X

Other

OtherConference on Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XI 2017
CountryUnited States
CityPortland
Period3/26/173/29/17

Fingerprint

aircraft structures
Corrosion
Precursor
Aircraft
corrosion
Carbon Fiber
Aluminum Alloy
carbon fibers
aluminum alloys
Carbon fibers
Aluminum alloys
Polymers
Aluminum
aircraft
polymers
aircraft reliability
structural reliability
high strength alloys
aluminum
Structural Reliability

All Science Journal Classification (ASJC) codes

  • Electronic, Optical and Magnetic Materials
  • Condensed Matter Physics
  • Computer Science Applications
  • Applied Mathematics
  • Electrical and Electronic Engineering

Cite this

James, R., Kim, T. H., & Narayanan, R. M. (2017). Prognostic investigation of galvanic corrosion precursors in aircraft structures and their detection strategy. In T-Y. Yu, H. F. Wu, P. J. Shull, & A. L. Gyekenyesi (Eds.), Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, and Civil Infrastructure 2017 [101690C] (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 10169). SPIE. https://doi.org/10.1117/12.2259797
James, Robin ; Kim, Tae Hee ; Narayanan, Ram Mohan. / Prognostic investigation of galvanic corrosion precursors in aircraft structures and their detection strategy. Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, and Civil Infrastructure 2017. editor / Tzu-Yang Yu ; H. Felix Wu ; Peter J. Shull ; Andrew L. Gyekenyesi. SPIE, 2017. (Proceedings of SPIE - The International Society for Optical Engineering).
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abstract = "Aluminum alloys have been the dominant materials for aerospace construction in the past fifty years due to their light weight, forming and alloying, and relative low cost in comparison to titanium and composites. However, in recent years, carbon fiber reinforced polymers (CFRPs) and honeycomb materials have been used in aircrafts in the quest to attain lower weight, high temperature resistance, and better fuel efficiency. When these two materials are coupled together, the structural strength of the aircraft is unparalleled, but this comes at a price, namely galvanic corrosion. Previous experimental results have shown that when CFRP composite materials are joined with high strength aluminum alloys (AA7075-T6 or AA2024-T3), galvanic corrosion occurs at the material interfaces, and the aluminum is in greater danger of corroding, particularly since carbon and aluminum are on the opposite ends of the galvanic series. In this paper, we explore the occurrence of the recognizable precursors of galvanic corrosion when CFRP plate is coupled to an aluminum alloy using SS-304 bolts and exposed to environmental degradation, which creates significant concerns for aircraft structural reliability. The galvanic corrosion software package, BEASY, is used to simulate the growth of corrosion in the designed specimen after which a microwave non-destructive testing (NDT) technique is explored to detect corrosion defects that appear at the interface of this galvanic couple. This paper also explores a loaded waveguide technique to determine the dielectric constant of the final corrosion product at the Q-band millimeter-wave frequency range (33-50 GHz), as this can be an invaluable asset in developing early detection strategies.",
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James, R, Kim, TH & Narayanan, RM 2017, Prognostic investigation of galvanic corrosion precursors in aircraft structures and their detection strategy. in T-Y Yu, HF Wu, PJ Shull & AL Gyekenyesi (eds), Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, and Civil Infrastructure 2017., 101690C, Proceedings of SPIE - The International Society for Optical Engineering, vol. 10169, SPIE, Conference on Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XI 2017, Portland, United States, 3/26/17. https://doi.org/10.1117/12.2259797

Prognostic investigation of galvanic corrosion precursors in aircraft structures and their detection strategy. / James, Robin; Kim, Tae Hee; Narayanan, Ram Mohan.

Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, and Civil Infrastructure 2017. ed. / Tzu-Yang Yu; H. Felix Wu; Peter J. Shull; Andrew L. Gyekenyesi. SPIE, 2017. 101690C (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 10169).

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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N2 - Aluminum alloys have been the dominant materials for aerospace construction in the past fifty years due to their light weight, forming and alloying, and relative low cost in comparison to titanium and composites. However, in recent years, carbon fiber reinforced polymers (CFRPs) and honeycomb materials have been used in aircrafts in the quest to attain lower weight, high temperature resistance, and better fuel efficiency. When these two materials are coupled together, the structural strength of the aircraft is unparalleled, but this comes at a price, namely galvanic corrosion. Previous experimental results have shown that when CFRP composite materials are joined with high strength aluminum alloys (AA7075-T6 or AA2024-T3), galvanic corrosion occurs at the material interfaces, and the aluminum is in greater danger of corroding, particularly since carbon and aluminum are on the opposite ends of the galvanic series. In this paper, we explore the occurrence of the recognizable precursors of galvanic corrosion when CFRP plate is coupled to an aluminum alloy using SS-304 bolts and exposed to environmental degradation, which creates significant concerns for aircraft structural reliability. The galvanic corrosion software package, BEASY, is used to simulate the growth of corrosion in the designed specimen after which a microwave non-destructive testing (NDT) technique is explored to detect corrosion defects that appear at the interface of this galvanic couple. This paper also explores a loaded waveguide technique to determine the dielectric constant of the final corrosion product at the Q-band millimeter-wave frequency range (33-50 GHz), as this can be an invaluable asset in developing early detection strategies.

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James R, Kim TH, Narayanan RM. Prognostic investigation of galvanic corrosion precursors in aircraft structures and their detection strategy. In Yu T-Y, Wu HF, Shull PJ, Gyekenyesi AL, editors, Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, and Civil Infrastructure 2017. SPIE. 2017. 101690C. (Proceedings of SPIE - The International Society for Optical Engineering). https://doi.org/10.1117/12.2259797