Cladding of Aircraft Parts

Cladding is a process used in the aerospace industry to enhance the corrosion resistance and durability of aircraft components. It involves bonding a thin layer of corrosion-resistant metal, typically pure aluminum, onto a stronger but more corrosion-prone alloy, such as aluminum alloys (e.g., 2024, 7075). This protective layer helps extend the lifespan of aircraft structures while maintaining their strength and lightweight properties.

How Cladding Works

1. Roll Bonding (Most Common Method) A thin layer of pure aluminum (e.g., Al 1100 or 1230) is metallurgically bonded to an aluminum alloy core during the rolling process. High pressure and heat ensure a strong bond between layers.
2. Explosion Bonding (For Specialty Applications) High-energy explosions force metal layers together to create a strong metallurgical bond.
3. Electroplating & Vapor Deposition Less common for large aircraft structures but used for specific components needing thin, precise coatings.

Applications in Aerospace

✔ Fuselage and Wing Skins – Clad aluminum sheets protect structural components from corrosion. ✔ Fuel Tanks & Internal Structures – Helps prevent fuel contamination from metal corrosion. ✔ Fasteners & Small Components – Clad materials used in bolts and brackets for corrosion resistance.

Benefits of Cladding in Aircraft

✅ Enhanced Corrosion Resistance – Pure aluminum forms a natural oxide layer, protecting the alloy core. ✅ Maintains Structural Strength – Allows the use of high-strength alloys without sacrificing durability. ✅ Lightweight Protection – Adds minimal weight compared to other corrosion-prevention methods. ✅ Self-Healing Properties – The aluminum oxide layer regenerates if slightly damaged.

Clad Aluminum vs. Bare Aluminum

• Clad Aluminum (e.g., Alclad 2024, Alclad 7075) Better corrosion resistance Slightly reduced strength compared to bare aluminum
  • Better corrosion resistance
  • Slightly reduced strength compared to bare aluminum
• Bare Aluminum Higher strength Requires additional corrosion protection (e.g., anodizing, painting)
  • Higher strength
  • Requires additional corrosion protection (e.g., anodizing, painting)

Standards & Specifications

• AMS 4013, AMS 4045 – Aerospace Material Standards for clad aluminum sheets.
• MIL-DTL-38999 – Military specification for corrosion-resistant aerospace materials.