The atmospheric corrosion of epoxy prime coated aluminum alloy 7075-T6 exposed for 7, 12 and 20 years was investigated. The remaining thicknesses of epoxy prime coatings for macroscopically intact coating areas followed a normal distribution and decreased linearly. EIS results demonstrated that the corrosion resistance of the coating decreased with exposure time. After 20 years of exposure, the epoxy coating had lost its protection as cracks existed within the coating and exfoliation corrosion had occurred on the substrate. The substrate was sensitive to exfoliation corrosion through metallographic and TEM analysis. The corrosion products were mainly hydroxides of aluminum. The morphology and chemical compositions of the coating bubbling area and propagation characterizations of exfoliation corrosion were analyzed by SEM, EPMA and EDS. Cracks between the lumps of corrosion products provided the channels for the transmission of corrosion mediums. Furthermore, the mechanical model was proposed to analyze the propagation characterization of exfoliation corrosion.

Aircraft are subjected to extreme weather conditions in coastal areas. This study reports long-term atmospheric exposure tests carried out on an epoxy primer-coated aluminum alloy in a coastal environment for 7, 12, and 20 years. The micromorphology and characteristics of the section and surface, the products of corrosion, electrochemical impedance, and molecular structure of the coated specimens were examined through a spectrophotometer, scanning electron microscopy (SEM), atomic force microscopy (AFM), X-ray diffraction (XRD), electrochemical impedance spectroscopy (EIS), and X-ray photoelectron spectrometer (XPS). The results showed that the angles of contact of the specimens with different numbers of years of atmospheric exposure satisfied the normal distribution. Their fractal dimensions increased with an increase in the duration of exposure. Intergranular corrosion and exfoliation corrosion appeared in the specimens after 20 years, where the product of corrosion was Al(OH)₃. The impedances and thermal properties of the epoxy coatings were influenced by the synergistic effects of aging and post-curing. The impedances of the coatings decreased greatly after long-term atmospheric exposure. After 20 years of corrosion, the specimen showed the characteristics of the substrate being corroded. The mechanism of corrosion and the electrochemical equivalent circuit were also analyzed.

CCF300/5228A aero composite stiffened panels achieved absorbing saturation in hygrothermal condition (70℃ distilled water), whose absorbing process followed the Fick law. Many debonding and gaps of matrix to fibers could be observed after hygrothermal exposure by scanning electron microscope (SEM). Compressive experiments were conducted on unaged and aged composite stiffened panels. Failure modes of the two types of specimens are quite similar with several major ways, including the debonding and fracture of stiffeners together with the splitting and ripping of panel. Buckling patterns for both types of specimens are similar and characterized by buckling of panels between stiffeners and buckling of the middle two stiffeners. However, the bending direction of buckling mid-panel for aged specimens is opposite to that of the unaged at same position panel, which shows that hygrothermal condition influences the bending direction of buckling mid-panels seriously. There still exists a post-buckling process for aged specimens under axial compression, whose average buckling load and failure load decrease by 3.1% and 22.2% respectively, comparing to that of unaged specimens.