Modeling and Property Measurement Tools for Corrosion Resistant Aircraft Design and Maintenance

Design for corrosion resistance and corrosion prediction for maintenance planning are both required to achieve sustainment cost and operational readiness objectives over the life cycle of an aircraft. Mixed material aircraft structures are susceptible to galvanic corrosion, and it is estimated that more than 80% of aircraft fatigue damage initiates by galvanic corrosion. To improve design and maintenance processes, Luna, teamed with Boeing and the University of Virginia, proposes to develop modeling and standard characterization tools that accurately predict the severity of galvanic corrosion under atmospheric conditions based on material combinations, geometry, and environment. An open source multiphysics model using electrochemical and environmental inputs to predict galvanic corrosion on surfaces and at interfaces of multi-material assemblies will be developed and validated. The model will have an open architecture and use standardized characterization data that is relevant to atmospheric thin films and crevice corrosion conditions. The modeling tool will be useful for design optimization, specifying corrosion protection systems, and identifying corrosion hot-spots. Using environmental conditions and cumulative exposure information for individual aircraft being established by the U.S. Air Force for CBM+, the galvanic corrosion model will be useful for predicting corrosion damage to tailor maintenance and sustainment activities.