Economic analysis and environmental impact of anti-corrosive protection systems in a full-scale aeronautical fuselage part from aluminium – copper – lithium alloy

A standard corrosion protection system for aluminium alloys for the aerospace sector typically involves anodization—forming a protective oxide layer on the alloy surface—followed by the application of a coating through spray painting. Hexavalent chromium has traditionally been employed in both processes due to its proven effectiveness and reliability. This investigation compares the costs of the conventional, yet hazardous, chromic protection system applied to the AA2024 alloy with the modern, chromium-free sulfuric acid protection system used on the AA2198 aircraft demonstrator. The findings of the investigation indicate that the sulfuric acid protection system offers both greater economic benefits and improved environmental sustainability, while also eliminating the need for hexavalent chromium in aluminium alloy protection systems.