Aircraft Corrosion Inspection Checklist [FREE PDF]

Aircraft corrosion inspection is mandated under FAA 14 CFR Part 43 Appendix D, requiring thorough examination of all structural components, control surfaces, and critical areas prone to corrosion. Failure to detect and treat corrosion can compromise airworthiness and structural integrity, leading to potential catastrophic failures. This checklist provides a systematic, regulation-aligned process to identify, document, and remediate corrosion in accordance with FAA and manufacturer maintenance ma

  • Industry: Aircraft Maintenance
  • Frequency: Monthly
  • Estimated Time: 60-90 minutes
  • Role: Aircraft Mechanic
  • Total Items: 33
  • Compliance: FAA 14 CFR Part 43 Appendix D, FAA 14 CFR Part 43.13, FAA 14 CFR Part 145.109, FAA AC 43-4B Corrosion Control for Aircraft, FAA 14 CFR Part 43.9

Fuselage Exterior Inspection

Inspect the outer skin of the fuselage for surface corrosion, pitting, and paint breakdown.

  • Is the fuselage exterior skin free from visible surface corrosion or pitting?
  • Is the exterior paint film intact with no bubbling, flaking, or discoloration indicating subsurface corrosion?
  • Are all skin lap joints and fastener rows free from corrosion deposits or white powdery residue?
  • Have corrosion-prone low-point drain areas on the fuselage belly been inspected and confirmed clear?
  • Are any corrosion findings documented with location, severity level, and corrective action required?
  • Describe the location and nature of any fuselage exterior corrosion found.

Wings and Control Surfaces

Examine wing skins, spars, ribs, ailerons, flaps, and associated hinge points for corrosion.

  • Are wing upper and lower skins free from corrosion, especially in the fuel tank vent and drain areas?
  • Are aileron and flap hinge brackets and attach points free from corrosion and structural degradation?
  • Are leading edge surfaces and any de-ice boot attachment areas free from corrosion or delamination?
  • Have wing root fairings and attachment areas been inspected for trapped moisture and corrosion?
  • Are all wing inspection panels and fasteners free from corrosion and properly sealed?

Landing Gear and Wheel Wells

Inspect landing gear assemblies, actuators, wheel wells, and related structure for corrosion damage.

  • Are main and nose landing gear strut chrome surfaces free from pitting, rust, or corrosion?
  • Are wheel well structural frames, brackets, and skin panels free from corrosion and paint damage?
  • Are landing gear retraction mechanism components, links, and pins free from corrosion and wear?
  • Are all landing gear electrical components, wiring harnesses, and connectors free from corrosion?
  • Have all landing gear drain holes been verified open and free from corrosion buildup?
  • What corrosion treatment or inhibitor has been applied to landing gear components during this inspection?

Engine Nacelles and Pylons

Inspect engine cowlings, nacelle structure, and pylon attachment areas for corrosion.

  • Are engine cowling panels, frames, and latches free from corrosion and structural damage?
  • Is the nacelle firewall free from corrosion, burns, or structural compromise?
  • Are pylon-to-wing attachment fittings and fasteners free from corrosion and fretting?
  • Are nacelle drain masts and overboard drain lines clear of corrosion and unobstructed?
  • Is the engine bleed air ducting and surrounding nacelle area free from signs of hot corrosion or heat damage?

Interior Structure and Bilge Areas

Inspect interior fuselage frames, floor structure, and bilge areas for hidden corrosion.

  • Are fuselage frames and stringers in cargo and bilge areas free from corrosion?
  • Are floor panels and support structure under galley and lavatory areas free from corrosion?
  • Is the pressure vessel skin and stringer interface free from corrosion, particularly near window belt areas?
  • Have bilge drain paths been verified clear of corrosion debris and standing fluid?
  • Are all previously treated corrosion areas showing no signs of recurrence or growth?

Corrosion Treatment and Corrective Action

Verify corrosion treatment methods, materials used, and proper maintenance record documentation.

  • Have all corrosion findings been treated using FAA-approved methods and materials per the maintenance manual?
  • Has corrosion removal been verified to be within allowable damage limits per the Structural Repair Manual (SRM)?
  • Have all treated areas been properly primed and top-coated with approved corrosion-inhibiting compounds?
  • Has the corrosion inspection and all findings been recorded in the aircraft permanent maintenance record?
  • Has the certifying mechanic signed and dated the return-to-service entry with certificate number?
  • Provide additional notes on corrosion findings, severity classifications, and corrective actions taken.

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Why Use This Aircraft Corrosion Inspection Checklist [FREE PDF]?

This aircraft corrosion inspection checklist [free pdf] helps aircraft maintenance teams maintain compliance and operational excellence. Designed for aircraft mechanic professionals, this checklist covers 33 critical inspection points across 6 sections. Recommended frequency: monthly.

Ensures compliance with FAA 14 CFR Part 43 Appendix D, FAA 14 CFR Part 43.13, FAA 14 CFR Part 145.109, FAA AC 43-4B Corrosion Control for Aircraft, FAA 14 CFR Part 43.9. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Aircraft Corrosion Inspection Checklist [FREE PDF] cover?

This checklist covers 33 inspection items across 6 sections: Fuselage Exterior Inspection, Wings and Control Surfaces, Landing Gear and Wheel Wells, Engine Nacelles and Pylons, Interior Structure and Bilge Areas, Corrosion Treatment and Corrective Action. It is designed for aircraft maintenance operations and compliance.

How often should this checklist be completed?

This checklist should be completed monthly. Each completion takes approximately 60-90 minutes.

Who should use this Aircraft Corrosion Inspection Checklist [FREE PDF]?

This checklist is designed for Aircraft Mechanic professionals in the aircraft maintenance industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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