Corrosion Resistance in Aircraft: Evaluating Zirconium and Niobium Coatings for Fasteners and Leading-Edge Protection

Abstract

Introduction

1. Corrosion in Aircraft:
Aircraft operate in harsh environments that accelerate corrosion due to factors like humidity, salt, fuel residues, and extreme temperatures. This compromises structural integrity, increases maintenance costs, and poses safety risks—especially in critical areas like wing edges and fasteners.

Types of corrosion commonly affecting aircraft include:

• Pitting corrosion (localized damage),

• Galvanic corrosion (between dissimilar metals),

• Stress corrosion cracking (under tensile stress),

• Filiform corrosion (under paint layers).

Environmental contributors include moisture, de-icing chemicals, and temperature variations. Maintenance and advanced coatings are vital for aircraft longevity and safety.

2. Protective Coatings for Corrosion Resistance:
A variety of coatings and treatments are used to protect aircraft and industrial components:

• Chromate-based coatings offer strong protection but are being phased out due to toxicity.

• Eco-friendly alternatives (zirconium, cerium-based) provide safer corrosion resistance.

• Ceramic and thermal spray coatings (e.g., ZrO?, Al?O?) deliver high durability in engine and high-temperature areas.

Long-term strategies include regular inspections, the use of self-healing coatings, and sensors for early corrosion detection.

3. Zirconium (Zr) and Niobium (Nb)-Based Coatings:
These materials offer excellent corrosion and wear resistance:

• Zirconium oxide (ZrO?): Forms a stable, corrosion-resistant barrier. Widely used in marine, medical, and chemical applications.

• Niobium carbide (NbC): High hardness and thermal stability, ideal for high-stress, high-temperature environments.

Application methods:

• ZrO?: Often applied via sol-gel, HVOF, or EBPVD for uniform coatings.

• NbC: Applied using PVD, CVD, or laser cladding, offering strong adhesion and wear protection.

Performance comparison:

• ZrO? excels in acidic and saline environments but may degrade under mechanical wear.

• NbC performs better under abrasion and heat, making it suitable for turbines, engines, and tools.

4. Industrial Applications and Durability:
Protective coatings are essential in various industries (aerospace, marine, automotive, energy) to shield components from corrosion and mechanical damage. Coating methods like thermal spray, chemical vapor deposition, and plasma spraying enhance resistance and lifespan.

Surface treatments (e.g., shot peening, nitriding) are often combined with coatings for improved fatigue and wear resistance.

Challenges include ensuring coating adhesion, preventing delamination, and resisting UV and chemical degradation. Innovations like multi-layer and self-healing coatings are under development to improve performance and longevity.

5. Case Studies and Research Insights:
Extensive research supports the effectiveness of advanced coatings:

• ZrO? and NbC coatings enhance corrosion and wear resistance across different substrates.

• Nanocomposite and multilayer coatings significantly improve material durability in aerospace, biomedical, and industrial environments.

• Studies show improved outcomes in orthodontics, marine hardware, and even nuclear applications through optimized coating strategies.

Conclusion

Corrosion is a major concern for aircraft and industrial components. Advances in zirconium and niobium-based coatings—alongside evolving application techniques and smart surface treatments—play a crucial role in enhancing durability, reducing maintenance, and ensuring safety in extreme operating conditions.

References

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Copyright

Copyright © 2025 Prajeesh Raj V, Shehna S, Anilu Anil, Gayathri Suresh, Revathy N B. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.