NAVAIR 01-1A-509-1.pdf - Navy BMR

1 NAVAIR 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-1 TECHNICAL MANUALCLEANING AND corrosion CONTROLVOLUME ICORROSION PROGRAM ANDCORROSION THEORY01 MARCH 2005 This publication supersedes NAVAIR 01-1A-509/TM 1-1500-344-23, dated 1 May 2001and NAVAIR 16-1-540/TM 1-1500-343-23/TO 1-1-689, dated 1 Sep STATEMENT A. Approved for public release; distribution is NOTICE - For unclassified, limited documents, destroy by any method that will preventdisclosure of contents or reconstruction of the BY DIRECTION OF COMMANDER, NAVAL AIR SYSTEMS COMMAND0801LP1043459 NATEC ELECTRONIC MANUALNAVAIR 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-1ii01 March 2005 LIST OF EFFECTIVE PAGESD ates of issue for original and changed pages 0 .. 01 Mar x .. xx XXX 199 XInsert latest changed pages; dispose of superseded pages in accordance with applicable : On a changed page, the portion of the text affected by the latest change is indicated be a vertical line, orother change symbol in the outer margin of the page.

2 Change in illustrations are indicated by miniature pointinghands. Changes to wiring diagrams are indicated by shaded number of pages in this manual is 52, consisting of the following:Page*ChangePage*ChangePage* 0 .. 15 Sep x .. xx XXX 199 XAChange X*Zero in this column indicates an original 0A .. 0i-ii .. 0 TPDR-2 01-1 - 01-4 02-1 - 03-1 - 03-26 0 Glossary-1 - 0 Index-1 - 0 Index-4 0 NAVAIR 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-1i01 March 2005 LIST OF ILLUSTRATIONS .. iiLIST OF TABLES .. iiLIST OF TECHNICAL PUBLICATIONSDEFICIANCE REPORTS (TPDR)INCORPORATED .. of and 1-21-7 Reporting Errors and Change and 1-32 PREVENTATIVE Prevention Philosophy .. PreventiveMaintenance PreventiveMaintenance control FailureData 2-43 corrosion of of of Influencing of Affected by of of Environment Glossary-1 ALPHABETICAL OF CONTENTSC hapterPageChapterPageNAVAIR 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-1ii01 March 2005 LIST OF TABLEST ableTitlePageTableTitlePage1-1.

3 Outline of Manual - All 1-11-2. Outline of volume of corrosion on of Deterioration on 3-17 FigureTitlePageFigureTitlePageLIST OF Prevention Maintenance corrosion of corrosion by Applicationof an Organic Film to a Metal of Sea Water onGalvanic Series of Metals andAlloys in Sea corrosion in a Flashlight Battery .. of Area Relationship inDissimilar Metal corrosion on Frequency Test Set .. corrosion of MagnesiumAdjacent to a Steel in the Cross-SectionalShape of corrosion of an Aluminum Wing of 7075-T6 Aluminum Alloy .. Electron Micrograph of aCorroding Aluminum corrosion of7075-T6 Aluminum Adjacent toSteel Example of Exfoliation atEdge of Adjacent to corrosion corrosion Found Under PaintCoating on a Magnesium of the Development of FiliformCorrosion on an Aluminum (Typical of Stress corrosion orCorrosion Fatigue).

4 corrosion on corrosion on Engine Surface corrosion corrosion corrosion Changes in Titanium Due Plated Surface Chromium Circuit Growth on Helicopter 3-213-3. Effects of Moisture and Fungi on of Airframe Flluid 3-24 NAVAIR 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-1iii01 March 2005 NONER eport control Number (RCN)Locationalskjalkj0000/00000Pg x-xx0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxReport control Number (RCN)LocationAIMD NAS PENSACOLA, FL52814-2000-0022Pg 9-2alskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxalskjalkj0000/00000Pg x-xxLIST OF TECHNICAL PUBLICATIONS DEFICIENCY REPORTS INCORPORATEDTPDR-1/(TPDR-2 Blank)

5 NAVAIR 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-1iv01 March 2005 TPDR-2 THIS PAGE LEFT INTENTIONALLY BLANK1-1 NAVAIR 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-101 March 2005 CHAPTER Prevention and repair of corrosiondamage to aircraft and avionic systems continues to bean ever increasing cost and safety burden for militaryaircraft. Equipment is routinely exposed to changes intemperature and pressure, varying humidity levels,dust, dirt, ultraviolet light, aircraft fluids, and environmentsthat promote corrosion . Increasing environmental andsafety restrictions, which limit traditional corrosion controlmaterials, are also a significant factor in the safe andeconomic operation of aircraft and cleaning and corrosion control manualwas established jointly by the Navy, Air Force, and Armyas a combined effort to consolidate and coordinatecorrosion control best practices for aircraft and volumized set of corrosion manualscombines and replaces the former Aircraft WeaponsSystems cleaning and corrosion control ( NAVAIR 01-1A-509/TM 1-1500-344-23) and Avionics cleaning andCorrosion Prevention/ control ( NAVAIR 16-1-540/TO1-1-689/TM 1-1500-343-23)

6 The purpose of this manual is toprovide information on materials and procedures toprevent, control , and repair corrosion damage to aircraftand avionics on land or at SCOPE. The material in this manual containsbasic corrosion prevention and corrective maintenanceinformation to be used at Organizational, Intermediate,and Depot OF OF ALL VOLUMES. The NAVAIR01-1A-509/TM 1-1500-343-23/TO 1-1-689 series ofmanuals is arranged as shown in Table A complete set of manuals to perform aircraftcleaning and corrosion control functions consists ofVolumes I, II, and IV (replaces NAVAIR 01-1A-509/TM 1-1500-344-23). A complete set of manuals to perform avionicsand electronics cleaning and corrosion control functionsconsists of Volumes I, III, and IV (Navy and Army) orVolumes I, III, and V (Air Force) (replacesNAVAIR 16-1-540/TM 1-1500-343-23/TO 1-1-689).

7 This volume was prepared under the technical cognizance of theMaterials Engineering Division, NAVAIR North Island, San Diego, 1-1. Outline of Manual - All VolumesEMULOVELTITNOITPIRCSEDFEIRBI yroehTnoisorroCdnamargorPnoisorroCsnialp xednanoitamrofnimargorpllarevosedivorpem ulovsihTotwohdna,ekatnactismrofeht,srucc otiyhw, , ,noitamrofnigniredrosedivorpdna,lortnoc1 -2 NAVAIR 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-101 March OF volume I. volume Iconsists of three chapters and a glossary, arranged asshown in Table RELATED PUBLICATIONS. A listing of relatedpublications is provided in Chapter 1 of each volume ofthis manual, as AND and maintenance personnel shalluse this manual as a guide for all corrosion control andmaintenance efforts. Contractors who maintain andrepair corrosion for military aircraft and avionics shallalso comply with the requirements of this manual shall be used in conjunction withand in support of the appropriate Army TechnicalManuals (TMs), Technical Bulletins (TBs), Departmentof the Army Pamphlets (DA PAMs), Navy MaintenanceInstruction Manuals (MIMs), Navy Structural RepairManuals (SRMs), Maintenance Requirement Cards(MRCs), or Air Force Technical Orders (TOs).

8 In the case of a conflict between this manualand other Navy manuals, this manual shall takeprecedence; however, maintenance activities shallcontact the appropriate Cognizant Field Activity (CFA)/Fleet Support Team (FST) for immediate resolution ofthe Army and Air Force specific systems/components manuals shall take precedence over The following definitions are adheredto in preparing this is used when a procedure is is used when a procedure isrecommended but not indicates future action but does not indicatea mandatory May is used only when a procedure is (WARNINGS, CAUTIONS andNOTES). The following definitions apply to WARNINGS,CAUTIONS and NOTES found throughout the An operation or maintenanceprocedure, practice, condition, or statement, which ifnot strictly observed, could result in injury to or death ofpersonnel, or long term health hazards to An operating or maintenanceprocedure, practice, condition, or statement, which ifnot strictly observed, could result in damage/destructionof equipment or loss of mission An operating procedure, practice, orcondition which is essential to DESIGNATIONS.

9 Since this is a tri-service manual, not all sections apply to all within the text that does not apply to all threeservices is designated after the paragraph number asfollows: (N) NAVY ONLY, (A) ARMY ONLY, or (AF) AIRFORCE ONLY. Large sections that are service specificare included as appendices in the appropriate ERRORS AND All activities using this manual areinvited to submit recommended changes, additions, 1-2. Outline of volume IRETPAHCELTITNOITPIRCSEDFEIRB1noitcudort nIrofytilibisnopserehtdna,egasuetairporp pa,esoprupehtsnialpxeretpahcsihTemulovsi htfoeniltuodnaepocsehtstneserpnoitcessih t, , ,stnemeriuqer3yroehTnoisorroC,ekatnactis mrofsuoiraveht,sruccotiyhw, 01-1A-509-1TM 1-1500-344-23-1TO 1-1-689-101 March REPORTING changes, additions, or deletions shallbe reported as Navy personnel should submit recommendedchanges to the appropriate technical services facilityusing the reporting system outlined in Force personnel should refer to TO 00-5-1to report personnel should submit completed DA2028/2028-2 forms to Commander, Army Aviationand Missile Command, ATTN: AMSAM-MMC-MA-NP,Redstone Arsenal, AL 35898-5220.

10 Changes may alsobe submitted electronically via the Army website, , or via email CHANGE This manual is a tri-servicedocument, coordinated by the Materials EngineeringDivision, Naval Air Depot North Island, Code ,San Diego, CA. The following activities are responsiblefor maintaining this document: the Naval Air SystemsCommand, the Air Force corrosion Program Office,and the Army Aviation and Missile Command. Asnecessary, representatives from these activities shallmeet to review proposed engineering and logisticalchanges to this manual. Changes are approved by allservices, except for service-specific The Navy is the lead servicefor publication of this manual; therefore, the followingNavy publication change procedures Volumes will be updated periodicallyby the issuance of a revision, which is a completereplacement of all pages with all change Changes.