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

Changein environment?
A new series should be established.
- Complexing ions, pH, temperature, velocity ..
- Potential (SCE) of high-alloy STS in sea water
(SW)
Deaerated SW: -450 mV
SW with 200 ppb O2: -100 mV
Hot SW: 100 mV
Natural, aerated SW: 300 mV
Chlorinated SW: 600 mV

Ch i l l 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 0.5-2 S/cm
Stored distilled water 2-4 S/cm
Supply water 50-1500 S/cm
Sea water 40,000 S/cm
Sat. NaCl solution 250,000 S/cm
Sulfuric acid <800,000 S/cm
Molten salts 20,000-107 S/cm

(a) Large anode-small cathode in high conductivity electrolyte

(b) Large anode-small cathode in low conductivity electrolyte
(c) 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