GALVANIC CORROSION

Corrosion as a result of the electrical contact of different metals.

Galvanic series: understand and use it properly!

Insulate anode from cathode if possible.

Area ratio of anode and cathode is important.

Avoid unfavorable ratio of small anode to large cathode.
Weld metal, bolts & nuts, rivets should be more noble than the substrate

Understand noble metal coating concept.

Never just specify coat the anode only.

Careful in using copper tube, Hg-containing manometers.

Galvanic corrosion

Galvanic corrosion

STS/carbon steel

STS-Cu

CORROSION of Al LAMELLAE
Al-Cu

Al-STS

GALVANIC SERIES
Change

in environment?
A new series should be established.
- Complexing ions, pH, temperature, velocity ..
- Potential (SCE) of high-alloy STS in sea water
(SW)
Deaerated SW:
SW with 200 ppb O2:
Hot SW:
Natural, aerated SW:
Chlorinated SW:

Ch

i l

-450 mV
-100 mV
100 mV
300 mV
600 mV

i h

Galvanic Corrosion by Potential Reversal

bicarbonate, nitrate
sulfate
phosphate

Galvanic Corrosion by Copper Deposition

Cooling water systems: corrosion of steel after deposition of copper.

FORMS OF GALVANIC CORROSION

Contact corrosion

Deposition corrosion
Cathodic contamination of anode via deposition of more noble
metals or metal oxides

Reversal of potential

Thermogalvanic corrosion
Preferential attack at the hot area when metal is subjected to a
thermal gradient.

GALVANIC CORROSION CELL

Typical conductivity values:
Fresh distilled water
Stored distilled water
Supply water
Sea water
Sat. NaCl solution
Sulfuric acid
Molten salts
(a)
(b)
(c)

0.5-2 S/cm
2-4 S/cm
50-1500 S/cm
40,000 S/cm
250,000 S/cm
<800,000 S/cm
20,000-107 S/cm

Large anode-small cathode in high conductivity electrolyte

Large anode-small cathode in low conductivity electrolyte
Small anode large cathode

Insulation of the Anode from the Cathode

AREA EFFECT
Avoid unfavorable ratio of small anode to large cathode.

Weld metal, bolts & nuts, rivets should be more noble than the
substrate

EFFECT OF DESIGN

Aluminum
-STS

Copper
-brass

Bad design

Good design

NOBLE METAL COATING

If one of two metals in contact is to be coated, the more

noble metal (cathode) should be coated.

Severe pits in steel

No problem

MITIGATION OF GALVANIC CORROSION

Select combination of metals as close together as possible in the

galvanic series.

Insulate dissimilar metal whenever practical.

If coupling is unavoidable, avoid unfavorable area effect.

Design the anode part for occasional easy replacement.

Install a third metal which is anodic to both metals in galvanic

contact.

Apply coating with caution.

Add inhibitor, if possible, to decrease the aggressiveness.

Beneficial Application of
Galvanic Corrosion
Primary

batteries

Cathodic

protection: sacrificial action

Galvanized steel/Zn metallizing/Zn paints

Mg, Al, Zn anodes for CP
Silver

cleaning