Galvanic and Corrosion Compatibility Dissimilar Metal Corrosion Guide

Quality engineering and design requires an understanding of material compatibility.

Galvanic corrosion (some times called dissimilar metal corrosion) is the process by which
the materials in contact with each other oxidizes or corrodes. There are three conditions that
must exist for galvanic corrosion to occur. First there must be two electrochemically
dissimilar metals present. Second, there must be an electrically conductive path between the
two metals. And third, there must be a conductive path for the metal ions to move from the
more anodic metal to the more cathodic metal. If any one of these three conditions does not
exist, galvanic corrosion will not occur. Often when design requires that dissimilar metals
come in contact, the galvanic compatibility is managed by finishes and plating. The finishing
and plating selected facilitate the dissimilar materials being in contact and protect the base
materials from corrosion.

For harsh environments, such as outdoors, high humidity, and salt environments fall into
this category. Typically there should be not more than 0.15 V difference in the "Anodic
Index". For example; gold silver would have a difference of 0.15V being acceptable.

For normal environments, such as storage in warehouses or non-temperature and humidity

controlled environments. Typically there should not be more than 0.25 V difference in the
"Anodic Index".

For controlled environments, such that are temperature and humidity controlled, 0.50 V can
be tolerated. Caution should be maintained when deciding for this application as humidity
and temperature do vary from regions

ANODIC
METALLURGICAL CATEGORY
INDEX (V)

Gold, solid and plated, Gold-platinum alloy 0.00

Rhodium plated on silver-plated copper 0.05

Silver, solid or plated; monel metal. High nickel-

0.15
copper alloys

Nickel, solid or plated, titanium an s alloys, Monel 0.30

Copper, solid or plated; low brasses or bronzes; silver

solder; German silvery high copper-nickel alloys; 0.35
nickel-chromium alloys

Brass and bronzes 0.40

High brasses and bronzes 0.45

18% chromium type corrosion-resistant steels 0.50

Chromium plated; tin plated; 12% chromium type

0.60
corrosion-resistant steels

Tin-plate; tin-lead solder 0.65

 Lead, solid or plated; high lead alloys 0.70

Aluminum, wrought alloys of the 2000 Series 0.75

Iron, wrought, gray or malleable, plain carbon and low

0.85
alloy steels

Aluminum, wrought alloys other than 2000 Series

0.90
aluminum, cast alloys of the silicon type

Aluminum, cast alloys other than silicon type,

0.95
cadmium, plated and chromate

Hot-dip-zinc plate; galvanized steel 1.20

Zinc, wrought; zinc-base die-casting alloys; zinc

1.25
plated

Magnesium & magnesium-base alloys, cast or

1.75
wrought

Beryllium 1.85

Other documents of interest:

Corrosion Resistant Coatings

Galvanic Corrosion

Corrosion Resistant Coatings Overview

Industrial Coating Processes and Design
Industrial Coating Services Directory

Corrosion resistance coatings are available for most materials, surface types, and
application environments. Corrosion resistant coatings can significantly increase the usable
lifetime of materials while reducing maintenance and replacement costs. There are many
possible operating applications which will result in corrosion. The following are many
types of common corrosions which occur in applications;

Galvanic Corrosion
Stress Corrosion Cracking
General Corrosion
Localized Corrosion
Caustic Agent Corrosion

Galvanic corrosion is one of the most common forms of corrosions which does occur in
products. There are three conditions that must exist for galvanic corrosion to occur. First
there must be two electrochemically dissimilar metals present. Second, there must be an
electrically conductive path between the two metals. And third, there must be a conductive
path for the metal ions to move from the more anodic metal to the more cathodic metal.
Corrosion resistant coatings would be applied to eliminate one or more of the corrosion
 causing conditions.

Caustic agent corrosion is caused by corrosive impurities in gases, liquids, solids or any
combination of the three, which come in contact with a material. Most petrochemical
process gases contain a certain amount of impurities, which may dissolve into the water and
become corrosive. For example, hydrogen sulfide is a common impurity in cracked gas.
Usually these impurities are not corrosive in a dry condition, but when moisture is present,
they will dissolve into the water and form hazardous acidic vapor or droplets. With these
conditions present in the petrochemical process, applying corrosion resistant coatings is
imperative

Galvanic corrosion occurs when two dissimilar metals with different potentials are placed in
electrical contact in an electrolyte. It may also take place with one metal with heterogeneities
(dissimilarities) (for example, impurity inclusions, grains of different sizes, difference in
composition of grains, or differences in mechanical stress). A difference in electrical potential
exists between the different metals and serves as the driving force for electrical current flow
through the corrodant or electrolyte. This current results in corrosion of one of the metals.
The larger the potential difference, the greater the probability of galvanic corrosion. Galvanic
corrosion only causes deterioration of one of the metals. The less resistant, more active one
becomes the anodic (negative) corrosion site. The stronger, more noble one is cathodic
(positive) and protected. If there were no electrical contact, the two metals would be
uniformly attacked by the corrosive medium. This would then be called general corrosion.

For any particular medium, a list can be made arranging metals sequentially from most
active, or least noble, to passive, or most noble. See Galvanic Compatibility for design
applicability.

Galvanic corrosion is of particular concern in design and material selection. Material

selection is important because different metals come into contact with each other and may
form galvanic cells. Design is important to minimize differing flow conditions and resultant
areas of corrosion buildup.

In some instances, galvanic corrosion can be helpful in some applications. For example, if
pieces of zinc are attached to the bottom of a steel water tank, the zinc will become the anode,
and it will corrode. The steel in the tank becomes the cathode, and it will not be effected by
the corrosion. This technique is known as cathodic protection. The metal to be protected is
forced to become a cathode, and it will corrode at a much slower rate than the other metal,
which is used as a sacrificial anode.

General corrosion involving water and steel generally results from chemical action where
the steel surface oxidizes, forming iron oxide (rust). Many of the systems and components in
the plant are made from iron.

Some standard methods associated with material selection that protect against general
corrosion include:The use of corrosion-resistant materials such as stainless steel and nickel,
chromium, and molybdenum alloys. (Keep in mind that the corrosion is electrochemical by
nature, and the corrosion resistance of the stainless steels results from surface oxide films that
interfere with the electrochemical process.)

The use of protective coatings such as paints and epoxies.

The application of metallic and nonmetallic coatings or linings to the surface which protects
against corrosion, but allows the material to retain its structural strength (for example, a
carbon steel pressure vessel with stainless steel cladding as a liner).

Localized corrosion is defined as the selective removal of metal by corrosion at small areas or zones
on a metal surface in contact with a corrosive environment, usually a liquid. It usually takes place
when small local sites are attacked at a much higher rate than the rest of the original surface.
Localized corrosion takes place when corrosion works with other destructive processes such as
stress, fatigue, erosion, and other forms of chemical attack. Localized corrosion mechanisms can
cause more damage than any one of those destructive processes individually. There are many
different types of localized corrosion. Pitting, stress corrosion cracking, chloride stress corrosion,
caustic stress corrosion, primary side stress corrosion, heat exchanger tube denting, wastage, and
intergranular attack corrosion.

Recommended Minimum Thicknesses for Nickel or Chromium Finishes on Steel, Iron, and
Zinc Products

Minimum thickness

Service conditions Nickel Chromium Typical applications

Exposure indoors in
normally warm, dry
atmospheres with coating
subject to minimum wear or
abrasion Moderate:
exposure indoors in places
where condensation of
moisture may occur, for
example, in kitchens and
bathrooms
10 m 0.130.8 m Toaster bodies, rotisseries, waffle
(0.0004 in) (0.000005 bakers, oven doors and liners,
1520 m 0.00003 in) interior automobile hardware, trim
(0.0006 0.258 m for major appliances, hair dryers,
0.0008 in) (0.00001 fans, inexpensive utensils, coat and
0.00032 in) luggage racks, standing ashtrays,
interior trash containers, light
fixtures Steel and iron: stove tops,
oven liners, home, office, and
school furniture, bar stools, golf-
club shafts Zinc alloys: bathroom
accessories, cabinet hardware

Source: From Quality Metal Finishing Guide, Metal Finishing Suppliers' Association.

Related:

ASTM-B633, Zinc

Either a bright or dull finish is acceptable. Bright zinc plating closely resembles bright
chromium. However, bright zinc does not have the permanence of surface appearance. Zinc
coated steel will not rust even when exposed by scratches because of the galvanic protection
of the zinc. On weathering, zinc turns to a drab gray color. Zinc should be deposited directly
on the base metal (Nickel is permissible undercoat if base metal is a corrosion resisting steel).

The primary use of chromate finishes on zinc is to retard or prevent formation of white
corrosion products on zinc surfaces. The primary purpose of phosphate coating on zinc is to
provide a paint base.

Type I Without supplementary treatment.

Type II With supplementary chromate treatment.

Type III With supplementary colorless chromate treatment.

Type IV With phosphate conversion treatment.

Zinc coatings prevent oxidation of the protected metal by forming a barrier and by acting as a
sacrificial anode if this barrier is damaged. Zinc oxide is a fine white dust that (in contrast to
iron oxide ) does not cause a breakdown of the substrate's surface integrity as it is formed.
Indeed the zinc oxide, if undisturbed, can act as a barrier to further oxidation, in a way similar
to the protection afforded to aluminum and stainless steels by their oxide layers. The majority
of hardware parts are zinc plated, rather than cadmium plated

Mil-T-10727 Specification for Tin

MIL-T-10727B, MILITARY SPECIFICATION: TIN PLATING: ELECTRODEPOSITED

OR HOT-DIPPED, FOR FERROUS AND NONFERROUS METALS (02 APRL 1980) [S/S
BY ASTM-B545, ASTM-B339]., This specification covers the requirements for
electrodeposited tin and hot-dipped tin coatings on ferrous and nonferrous metals

Tin plating intended for engineering purposes is used for corrosion protection, to facilitate
soldering, to improve anti-galling characteristics, and as a stop-off barrier in the nitriding of
high-strength steels. Copper alloys containing more than 5% Zn shall have a copper
undercoating of at least 0.0001" or nickel undercoating of at least 0.000050".

Type I Electrodeposited. Reference ASTM B-545 Standard Specification for Electro-

deposited Coatings of Tin

Type II Hot-Dipped

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QQ-S-365D, FEDERAL SPECIFICATION: SILVER PLATING, ELECTRODEPOSITED,

GENERAL REQUIREMENTS FOR (03 JUN 1985) [S/S BY ASTM-B700]., This
specification covers the requirements for electrodeposited silver plate.

White to very bright in appearance. Good corrosion resistance, depending on base metal. Will
tarnish easily. Hardness varies from about 90 Brinnell to about 135 Brinnell depending on
process and plating conditions. Solderability is excellent, but decreases with age. Best
electrical conductor.
0.0005" min. unless otherwise specified Increasing use in both decorative and engineering
fields, including electrical and electronic fields.

Type I: Matte.
Type II: Semi-bright.
Type III: Bright.
Grade A: Chromate post-treatment to improve tarnish resistance.
Grade B: No supplementary treatment.
QQ-A-35, ASTM A967, AMS 2700 Passivate, Stainless, Steel - corrosion resistant
ASTM A967 replaces QQ-A-35.
This specification covers several different types of chemical passivation treatments
for stainless steel parts. It includes recommendations and precautions for descaling,
cleaning, and passivation of stainless steel parts. It includes several alternative tests,
with acceptance criteria, for confirmation of effectiveness of such treatments for
stainless steel parts
A process designed to remove foreign metals from the surface of stainless and
corrosion resistant steels of the 200, 300 and 400 series and precipitation hardened
corrosion-resistance steels. Does not change the appearance of the base metal. Process
purifies surface and therefore improves corrosion resistance.
Type II Medium temperature with sodium dichrominate.
Type VI Low temperature
Type VII Medium temperature
Type VIII Medium temperature with high concentration of nitric acid. High resistance
to corrosive environments.

DOD-P-16232-F, Heavy Phosphate Coating

Heavy Phosphate Coating is a coating for medium and low alloy steels. Gray to black in
color. Intended uses: The "heavy" phosphate coatings covered by this specification are
intended as a base for holding/retaining supplemental coatings which provide the major
portion of the corrosion resistance.

Heavy Type Z can be used up to 200 F, to prevent galling in extrusion and deep
drawing.
Class 2 is good for corrosion resistance.
Note: This specification lists a type M also
Type Z .0002" Zinc phosphate base coating
Class 1 .0005" Supplementary preservative treatment or coating, as specified.
Class 2 Supplementary treatment with preservative conforming to MIL-C-16173,
Grade 3 or MIL-L-3150 as alternate for very small parts.
Class 3 No supplementary treatment.
Class 4 Chemically converted.
(Aluminum, Copper, Steel, Stainless steel, Titanium, Chromium, Nickel)
MIL-A-8625F, MILITARY SPECIFICATION: ANODIC COATINGS FOR
ALUMINUM AND ALUMINUM ALLOYS (10 SEP 1993)., This specification
covers the requirements for six types and two classes of electrolytically formed anodic
coatings on aluminum and aluminum alloys for non-architectural applications
Hard anodizing is a term used to describe anodic coatings with surface hardness
and/or abrasion resistance as their primary characteristic. Great for surface to surface
sliding with low loads The color of the natural anodic coating depends on the alloy
 and the coating thickness. e.g. 6061 has a tan or gray color which darkens to almost
black at .003"; 6063 has an amber shade which darkens to bronze. Both are
considered clear. After hard anodizing surfaces may be sealed in boiling distilled
water, sodium dichromate solution, dewatering oil, wax or PTFE solutions
Class 1: Not dyed or pigmented.
Class 2: Dyed. (Specify color on Drawing).
Hard anodic oxide coatings find application in the engineering industry for
components which require a very wear resistant surface. " Flash" hard anodize may be
used instead of conventional anodize for corrosion resistance
AMS-2404C, AMS-2505B, AMS-2433B,
Electroless Nickel (Aluminum, Steel)
Similar to stainless steel in color. Plates uniformly in recesses and cavities (does not
build up on edges) sometimes called "Dog-boning". Corrosion resistance is good for
coatings over .001" thickness. Electroless nickel is used extensively in salvage of
mismachined parts. Also, for inside dimensions and irregular shapes (where assembly
tolerances need uniformity provided by electroless process). Coatings typically used
to provide a hard-ductile, wear-resistant and corrosion-resistant surface for operation
in service temperatures up to 1000F (538C). Previously Mil-C-26074 was the
industry specification.
Please note: The following is per. Mil-C-26074. This specification has been cancelled
but, is still used in industry.
Class 1 As coated
Class 2 Steel and other base metals heat treatable to improve hardness.
Class 3 Aluminum and other base metals not heat treatable
Class 4 Aluminum alloy, heat treatable, processed to improve adhesion of the nickel
deposit
Grade A .0010" min. Aluminum alloys will be grade A.
Grade B .0005" min.Cu, Ni, Co alloys will be grade B.
Grade C .0015" min. Ferrous alloys will be grade C.
Electroless Nickel - AMS-2404D / AMS-2405B
These AMS specs are similar. Ams- 2404D does not specify the phosphorous content
while the
AMS - 2405B says "P" to be 8% max. No specific hardness numbers defined by these
two specs on the EN deposit.
AMS-2404D Thickness as specified on drawing. Note: Unless a specific class is
specified,
Class 1 shall be supplied.
Class 1 Except for hydrogen embrittlement relief, no postplating thermal treatment.
Class 2 Thermal treatment at 450 F (232 C) or above to harden the deposit.
Class 3 Thermal treatment at 375 F (191 C) to verify adhesion for non-heat treatable
aluminum and beryllium alloys.
Class 4 Thermal treatment at 250 F (121 C) to verify adhesion for non-heat treatable
aluminum alloys.
Mil-A-8625, Chromic Anodize, (Aluminum)
Anodizing is a conversion of the aluminum surface to practically pure aluminum
oxide: the anodic coating. Type II is of particular interest to the designer wishing for
both the virtues of form and function. This anodic coating is significantly more
abrasion and corrosion resistant then the untreated metal. The coating thickness is a
combination of both penetration and build-up, in approximately a 50-50 ratio. This
coating may be subsequently dyed in a variety of colors, imparting a very decorative
 finish both in a satin and a polished surface result. Color will vary from light gray to
dark gray depending on alloy. Not as readily dyed as sulfuric anodize.
Aluminum alloys are anodized to increase corrosion resistance, to increase surface
hardness, and to allow dyeing (coloring), improved lubrication, or improved adhesion.
The anodic layer is non-conductive.
When exposed to air at room temperature, or any other gas containing oxygen, pure
aluminum self-passivates by forming a surface layer of amorphous aluminum oxide 2
to 3 nm thick, which provides very effective protection against corrosion. Aluminum
alloys typically form a thicker oxide layer, 5-15 nm thick, but tend to be more
susceptible to corrosion. Aluminum alloy parts are anodized to greatly increase the
thickness of this layer for corrosion resistance. The corrosion resistance of aluminum
alloys is significantly decreased by certain alloying elements or impurities: copper,
iron, and silicon, so 2000, 4000, and 6000-series alloys tend to be most susceptible.
Although anodizing produces a very regular and uniform coating, microscopic
fissures in the coating can lead to corrosion. Further, the coating is susceptible to
chemical dissolution in the presence of high and low pH chemistry, which results in
stripping the coating and corrosion of the substrate. To combat this, various
techniques have been developed either to reduce the number of fissures or to insert
more chemically stable compounds into the oxide, or both. For instance, sulfuric
anodized articles are normally sealed, either through hydro-thermal sealing or
precipitating sealing, to reduce porosity and interstitial pathways that allow for
corrosive ion exchange between the surface and the substrate. Precipitating seals
enhance chemical stability but are less effective in eliminating ion exchange
pathways. Most recently, new techniques to partially convert the amorphous oxide
coating into more stable micro-crystalline compounds have been developed that have
shown significant improvement based on shorter bond lengths.
Some aluminum aircraft parts architectural materials, and consumer products are
anodized. Anodized aluminum can be found on mp3 players, multi-tools, flashlights,
cookware, cameras, sporting goods, window frames, roofs, in electrolytic capacitors,
and on many other products both for corrosion resistance and the ability to retain dye.
Although anodizing only has moderate wear resistance, the deeper pores can better
retain a lubricating film than a smooth surface would.
Anodized coatings have a much lower thermal conductivity and coefficient of linear
expansion than aluminum As a result, the coating will crack from thermal stress if
exposed to temperatures above 80 C. The coating can crack, but it will not peel. The
melting point of aluminum oxide is 2050 C, much higher than pure aluminum's 658
C. (This and the non-conductivity of aluminum oxide can make welding more
difficult.) In typical commercial aluminum anodization processes, the aluminum
oxide is grown down into the surface and out from the surface by equal amounts. So
anodizing will increase the part dimensions on each surface by half the oxide
thickness. For example a coating that is (2 m) thick, will increase the part
dimensions by (1 m) per surface. If the part is anodized on all sides, then all linear
dimensions will increase by the oxide thickness. Anodized aluminum surfaces are
harder than aluminum but have low to moderate wear resistance, although this can be
improved with thickness and sealing.
Anodizing Process:
Preceding the anodization process, wrought alloys are cleaned in either a hot soak
cleaner or in a solvent bath and may be etched in sodium hydroxide (normally with
added sodium gluconate), ammonium bifluoride or brightened in a mix of acids. Cast
 alloys are normally best just cleaned due to the presence of intermetallic substances
unless they are a high purity alloy such as LM0.
The anodized aluminum layer is grown by passing a direct current through an
electrolytic solution, with the aluminum object serving as the anode (the positive
electrode). The current releases hydrogen at the cathode (the negative electrode) and
oxygen at the surface of the aluminum anode, creating a build-up of aluminum oxide.
Alternating current and pulsed current is also possible but rarely used. The voltage
required by various solutions may range from 1 to 300 V DC, although most fall in
the range of 15 to 21 V. Higher voltages are typically required for thicker coatings
formed in sulfuric and organic acid. The anodizing current varies with the area of
aluminum being anodized, and typically ranges from 30 to 300 amperes/meter (2.8 to
28 ampere/ft).
Aluminum anodizing is usually performed in an acid solution which slowly dissolves
the aluminum oxide. The acid action is balanced with the oxidation rate to form a
coating with nanopores, 10-150 nm in diameter. These pores are what allow the
electrolyte solution and current to reach the aluminum substrate and continue growing
the coating to greater thickness beyond what is produced by auto passivation.
However, these same pores will later permit air or water to reach the substrate and
initiate corrosion if not sealed. They are often filled with colored dyes and/or
corrosion inhibitors before sealing. Because the dye is only superficial, the underlying
oxide may continue to provide corrosion protection even if minor wear and scratches
may break through the dyed layer.
Conditions such as electrolyte concentration, acidity, solution temperature, and
current must be controlled to allow the formation of a consistent oxide layer. Harder,
thicker films tend to be produced by more dilute solutions at lower temperatures with
higher voltages and currents. The film thickness can range from under 0.5
micrometers for bright decorative work up to 150 micrometers for architectural
applications.
The anodic coating types and classes are:
Type I Chromic acid anodizing (conventional)
Type IB Chromic acid anodizing (low voltage method)
Type IC Non-chromic acid anodizing (for use as a non-chromate alternative for Type
I and IB coatings)
Type II Sulfuric acid anodizing (conventional)
Type IIB Sulfuric acid anodizing (for use as a non-chromate alternative for Type I and
IB coatings)
Type III Hard anodize
Class 1 Non-dyed
Class 2 Dyed
AMS 2472C listed as similar to this specification.
Type 1 & Type 1B coatings:
Class 1 200 Milligrams/sq.ft.
Because of thin deposit that will scratch easily. Can be used for inspection of
aluminum forgings or castings by noting evidence of chromic acid bleed out from
laps, cracks, seams, etc.
Typical thickness specified 0.00001"- 0.0007"
Type I Conventional coating produced from chromic acid bath. Unless otherwise
specified, coating will be sealed. Metal salt sealants should not be used on items that
will be painted.
Type 1 Low voltage chromic acid anodizing 22V.
 Class 1 Non-dyed (Natural, boiling D.I. water sealing).Class 2 Dyed.
Shall not be applied to aluminum alloys with over 5.0% copper, 7.0% silicon, or total
alloying constituents over 7.5%. When copper content is less than 4.6% and for all
suitable casting alloys be sure aluminum is tempered (such as -T4 or T6)
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QQ-N-290A, FEDERAL SPECIFICATION: NICKEL PLATING
(ELECTRODEPOSITED) (12 NOV 1971) [S/S BY SAE-AMS-QQ-N-290]., This
specification covers the requirements for electro-deposited nickel plating on steel,
copper and copper alloys, and zinc and zinc alloys.
QQ-N-290
Nickel can be deposited soft or hard - dull or bright, hardness can range from 150 -
500 Vickers. Can be similar to stainless steel in color, or can be a dull gray or light
gray (almost white) color. Corrosion resistance is a function of thickness. Has a low
coefficient of thermal expansion, and is magnetic.
Class 1 For corrosion protection. With typical 0.0002" copper undercoating prior to
the nickel plate.
Grade A .0016" min.
Grade B .0012" min.
Grade C .0010" min.
Grade D .0008" min.
Grade E .0006" min.
Grade F .0004" min.
Grade G .0002" min.
Class 2 .002" min.
Download Specification QQ-N-290
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TT-C-490, Light Phosphate Coating
Phosphate coatings provides for increased surface adhesion for painting.
Type I - Intended as a general all purpose pretreatment prior to painting
Typical .0002"- .0005" Light coating for use as paint base.
Method I Mechanical or abrasive cleaning
Method III Hot alkaline.
Method V alkaline de-rusting.

Mil-R-46085B, Rhodium

MIL-R-46085B, MILITARY SPECIFICATION: RHODIUM PLATING,

ELECTRODEPOSITED, (24 APR 1984) [NO S/S DOCUMENT]., This specification covers
the requirements for the electrodeposition of rhodium over metallic surfaces.

Metallic and similar to stainless steel in color. Excellent corrosion resistance. Almost as hard
as chromium. Very good abrasion resistance. Thicker coatings are very brittle. Has high
reflectivity. Used on silver for tarnish resistance. Applications range from electronics to nose
cones-wherever wear, corrosion resistance, solder-ability, and reflectivity are important.

Type I Over nickel, silver, gold, or platinum.

Type II Over other metals, (requires nickel undercoat).

Class 1 .000002" min.

 Class 2 .00001" min.
Class 3 .00002" min.
Class 4 .00010" min.
Class 5 .00025" min.
Mil-A-8625, Sulfuric Anodize, (Aluminum)
MIL-A-8625F, MILITARY SPECIFICATION: ANODIC COATINGS FOR
ALUMINUM AND ALUMINUM ALLOYS (10 SEP 1993)., This specification
covers the requirements for six types and two classes of electrolytically formed anodic
coatings on aluminum and aluminum alloys for non-architectural applications (see
6.1).
Color will vary with alloy. Aluminum with low alloying elements will show
practically no color change. Best coating on aluminum for dyeing. Can be dyed
practically any color or shade (black, blue, red, gold, orange, green etc.) Resistant to
salt environments.
(5% NaCI solution) per method B-117 of ASTM. Minimum weight for type II
coatings: Class 1 is 1,000 Milligrams/sq.ft.
Type II All aluminum alloys, but do not use where solution can be entrapped.
Type II B Light coating
Class 1 Non-dyed
Class 2 Dyed

Electroplating is a finishing process which a metallic coating is deposited onto a part. The
electroplating process is facilitated by applying a negative charge onto the part object and
immersing it into a salt solution of the metal to be deposited. The metallic ions of the salt
solutions are charged positive by applying a positive charge to the solution, and are drawn to
the negatively charged part. When they reach the part, the negatively charged part
will "reduce" the positively charged ions onto metallic part.

Electroplating is also called electrodedeposition. The electroplated plating metal is most

normally a single metallic element, not an alloy. However, some alloys can be
electrodeposited . Electroplating is used in many industries for function, corrosion control
and/or decorative purposes. Chrome-plating of steel parts on automobiles and motorcycles is
a common application of electroplating .

Other examples of electroplating applications are:

Steel parts such as camshafts, crankshafts, and hand tools resists wear better when
they are electroplated with chromium.
Steel or aluminum parts in light fixtures are often electroplated with nickel and
followed by chromium or brass.
Common steel bolts, nuts, and washers are electroplated with a coating of zinc.
Electroplating may deposit silver, copper or brass onto electrical connectors.

Electroplating Caution:

Not properly applying electroplating process and acid cleaning of springs, without proper
baking treatment, can cause spring steels to become brittle, called "Hydrogen embrittlement
" Nonferrous springs are immune do not share the same problem. In general, All
electroplated parts 1200 Mpa or higher should be baked at 190C for three hours or more
within four hours after electroplating, to ensure Hydrogen embrittlement relief.
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Mil-P-81728 Tin Lead

IL-P-81728A, MILITARY SPECIFICATION: PLATING, TIN LEAD

(ELECTRODEPOSITED) (13 FEB 1973) [S/S BY SAE-AMS-P-81728]., This specification
covers the requirements for electrodeposited tin-lead plating.

Either a satin or bright luster is acceptable. Has excellent solder-ability. 0.0002" copper plate
generally required on copper base alloys. No undercoating required on steel substrates unless
otherwise specified.

Typical specified thickness: .0002"-.0008"

AMS-2404C, AMS-2505B, AMS-2433B,

Electroless Nickel (Aluminum, Steel)

Similar to stainless steel in color. Plates uniformly in recesses and cavities (does not build up
on edges) sometimes called "Dog-boning". Corrosion resistance is good for coatings over
.001" thickness. Electroless nickel is used extensively in salvage of mis-machined parts.
Also, for inside dimensions and irregular shapes (where assembly tolerances need uniformity
provided by electroless process). Coatings typically used to provide a hard-ductile, wear-
resistant and corrosion-resistant surface for operation in service temperatures up to 1000F
(538C). Previously Mil-C-26074 was the industry specification.

Please note: The following is per. Mil-C-26074. This specification has been cancelled but, is
still used in industry.

Class 1 As coated

Class 2 Steel and other base metals heat treatable to improve hardness.

Class 3 Aluminum and other base metals not heat treatable

Class 4 Aluminum alloy, heat treatable, processed to improve adhesion of the nickel deposit

Grade A .0010" min. Aluminum alloys will be grade A.

Grade B .0005" min.Cu, Ni, Co alloys will be grade B.

Grade C .0015" min. Ferrous alloys will be grade C.

Electroless Nickel - AMS-2404D / AMS-2405B

These AMS specs are similar. Ams- 2404D does not specify the phosphorous content while
the

AMS - 2405B says "P" to be 8% max. No specific hardness numbers defined by these two
specs on the EN deposit.
AMS-2404D Thickness as specified on drawing. Note: Unless a specific class is specified,

Class 1 shall be supplied.

Class 1 Except for hydrogen embrittlement relief, no postplating thermal treatment.

Class 2 Thermal treatment at 450 F (232 C) or above to harden the deposit.

Class 3 Thermal treatment at 375 F (191 C) to verify adhesion for non-heat treatable
aluminum and beryllium alloys.

Class 4 Thermal treatment at 250 F (121 C) to verify adhesion for non-heat treatable
aluminum alloys.

Mil-C-14550, Copper, (Under Coat)

Copper in color and matte to a very shiny finish. Good corrosion resistance when used as
undercoat. A number of copper processes are available, each designed for a specific purpose:

Brightness (to eliminate the need for buffing)

High speed: (for electroforming)
Fine grain: (to prevent casehardening) Spec. Thickness
Class 00 .001 - .005
Class 1 .001 minimum thickness.
Class 2 .0005 minimum thickness. Typically used as an undercoat for nickel and
other platings.
Class 3 .0002 minimum thickness. To prevent basis metal migration into tin
(prevents poisoning solder-ability).
Class 40 .0001"To prevent basis metal migration into tin (prevents poisoning
solderability).

MIL-C-14550, MILITARY SPECIFICATION: COPPER PLATING

(ELECTRODEPOSITED) (02 DEC 1983) [S/S BY SAE-AMS2418]., This specification
covers electrodeposited copper plating on metal surfaces

QQ-C-320, Chrome, Chromium Plating

Chrome plating (less commonly chromium plating), often referred to simply as chrome, is a
technique of electroplating a thin layer of chromium onto a metal or plastic object. The
chromed layer can be decorative, provide corrosion resistance, ease cleaning procedures, or
increase surface hardness. Sometimes a less expensive imitator of chrome may be used for
aesthetic purposes.

Application Manufacturing
Chrome plating a component typically includes these stages:

Degreasing to remove heavy soiling

Manual cleaning to remove all residual traces of dirt and surface impurities
Various pretreatments depending on the substrate
 Placement into the chrome plating vat, where it is allowed to warm to solution
temperature
Application of plating current for the required time to attain the desired thickness

There are many variations to this process, depending on the type of substrate being plated.
Different substrates need different etching solutions, such as hydrochloric, hydrofluoric, and
sulfuric acids. Ferric chloride is also popular for the etching of Nimonic alloys. Sometimes
the component enters the chrome plating vat electrically live. Sometimes the component has a
conforming anode made from lead/tin or platinized titanium. A typical hard chrome vat plates
at about 1 mil (25 m) per hour.

Various linishing and buffing processes are used in preparing components for decorative
chrome plating. The overall appearance of decorative chrome plating is only as good as the
preparation of the component.

The chrome plating chemicals are very toxic. Disposal of chemicals is regulated in most
countries.

Specifications

Excellent hardness (Rc 68-74), wear resistance and erosion resistance. Has low coefficient of
friction, and is resistant to heat. In addition to above properties, can be rendered porous for
lubrication purposes.

Type I Bright

Type II Satin

Class 1 .00001" min. chrome on all visible surfaces. Corrosion protection finish or the
"Decorative" finish used in a conjunction with copper and nickel as under coatings prior to
the chrome finish.

Class 2 Thickness should be specified on requirements documents. Plate directly on base

metal.

Class 2a: Plated to specified dimensions or processed to specified dimensions after plating.

Class 2b: Parts below Rc 40 and subject to static loads or designed for limited life under
dynamic loads.

Class 2c: Parts below Rc 40 and designed for unlimited life under dynamic loads.

Class 2d: Parts have hardness of Rc 40 or above and subject to static loads or designed for
limited life under dynamic loads.

Class 2e: Parts have hardness of Rc 40 or above and are designed for unlimited life under
dynamic loads.

Mil-C-13924, Black Oxide Coating,

(Steel, Stainless Steel)
A black oxide finish offers a combination of properties that cannot be provided any other
way. This conversion coating does not change the dimensional, physical or mechanical
properties of the surface treated. The finish is inexpensive and easy to apply. It has an
excellent appearance and is abrasion resistant. A uniform black coating for ferrous metals.
Mostly a decorative coating. Only very limited corrosion protection under mild corrosion
conditions.

Black oxide coatings should normally be given a supplementary treatment (i.e. oil
displacement per Mil - C-16173 Grade 3 or protective treatments of Mil-C-16173).

No dimensional change effected. For moving parts which cannot tolerate the dimensional
change of a more corrosion resistant finish. For decorative applications and may also be used
to decrease light reflection.

Class 1 Alkaline Oxidizing. For wrought iron, cast and malleable irons, plain carbon, and low
alloy steels. For corrosion resistance steel alloys which are tempered at 900F (482C) or
higher.

Class 3 Fused salt oxidizing.

Class 4 Alkaline Oxidizing. For 300 series corrosion resistant steel alloys only.

Shall not be applied to aluminum alloys with over 5.0% copper, 7.0% silicon, or total
alloying constituents over 7.5%. When copper content is less than 4.6% and for all suitable
casting alloys be sure aluminum is tempered (such as -T4 or T6)

Mil-A-8625, Anodize, (Aluminum)

Anodizing is an electrochemical process that converts the metal surface into a decorative,
durable, corrosion-resistant, anodic oxide finish. Aluminum is ideally suited to anodizing,
although other nonferrous metals, such as magnesium and titanium, also can be anodized.

Anodizing increases corrosion resistance and wear resistance, and provides better adhesion
for paint primers and glues than does bare metal. Anodic films can also be used for a number
of cosmetic effects, either with thick porous coatings that can absorb dyes or with thin
transparent coatings that add interference effects to reflected light.

Anodizing is also used to prevent galling of threaded components and to make dielectric
films for electrolytic capacitors . Anodic films are most commonly applied to protect
aluminium alloys , although processes also exist for titanium , zinc , magnesium , niobium ,
zirconium , hafnium , and tantalum . Iron or carbon steel metal exfoliates when oxidized
under neutral or alkaline microelectrolytic conditions; i.e., the iron oxide (actually ferric
hydroxide or hydrated iron oxide , also known as rust ) forms by anoxic anodic pits and large
cathodic surface, these pits concentrate anions such as sulfate and chloride accelerating the
underlying metal to corrosion.

The color of the finished anodized product can vary in color. The AAC Color Standards
detail the specific testing procedures for anodic coating thickness, coating density and seal
integrity. These properties can be checked by the appropriate ASTM B244, ASTM B137,
ASTM B680, ISO 2360, or ISO 3210. The following are similar or carried under Mil-A-
8625F.

AMS-2468E Hard coat 0.002" AMS-2469D Hard coat 0.002".

AMS-2470H Chromic acid process.

AMS-2471D Sulfuric acid process - no dye coating.

AMS-2472C

AMS-2482A Hard coat 0.002" with Teflon.

Industrial Finishing Services

Industrial Coating Types, Processes Menu
Engineering Application & Design

The following finishes and plating descriptions are typical definitions as required by vendors.
Often Mil, AMS and other controlled specifications are not required as commercial adequate
processes are available through all vendors. Consult with your vendor on your particular
design requirement and needs.

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Mil-A-8625F, Anodize, (Aluminum) Electroplating Standards Specifications

Mil-C-13924C, Black Oxide Coating, (Steel, Mil-C-5541E, Chemical Films, Iridite,
Stainless Steel)
QQ-C-320B, Chrome, (Steel)
Mil-C-14550B, Copper, (Under Coat)
Electroless Nickel (Aluminum, Steel)
MIL-G-45203 Electroplating Gold
MIL-G-45204C, (GOLD)
QQ-A-290A, Nickel
TT-C-490, Light Phosphate Coating
Mil-R-46085B, Rhodium
Mil-A-8625C, Sulfuric Anodize, (Aluminum) Mil-T-10727C, Tin
Mil-T-81728A, Tin Lead
Electroplating About and Application
(Aluminum)
Mil-F-495E, Chemical Finish; Black,
(Copper)
Mil-A-8625, Chromic Anodize, (Aluminum)
AMS-2404C, AMS-2505B, AMS-2433B,
Electroless Nickel (Aluminum, Steel)
Electropolishing, (Stainless Steel)
Electropolishing - About Definition
Mil-A-8625F, (Aluminum, Copper, Steel,
Stainless steel, Titanium, Chromium, Nickel)
QQ-A-35C, Passivate,
(Stainless, Steel - corrosion resistant)
DOD-P-16232-F, Heavy Phosphate Coating
QQ-S-365D, Silver
ASTM-B633, Zinc
Electroplating Thickness Recommendation
Chart Table

Galvanic table
Details
 Hits: 7725

Galvanic corrosion
Galvanic series relationships are useful as a guide for selecting metals to be joined, will help
the selection of metals having minimal tendency to interact galvanically, or will indicate the
need or degree of protection to be applied to lessen the expected potential interactions. In
general, the further apart the materials are in the galvanic series, the higher the risk of
galvanic corrosion, which should be prevented by design. Conversely, the farther one metal is
from another, the greater the corrosion will be. However, the series does not provide any
information on the rate of galvanic corrosion and thus serves as a basic qualitative guide only.

The use of the galvanic series has to be done with caution and a basic knowledge of the
environments that is a necessary part of this serious form of corrosion. The following
documents provide different points of view regarding the ranking of metals and coatings in
practical schemes for preventing galvanic corrosion.

Galvanic Table

The following galvanic table lists metals in the order of their relative activity in seawater
environment. The list begins with the more active (anodic) metal and proceeds down the to
the least active (cathodic) metal of the galvanic series. A "galvanic series" applies to a
particular electrolyte solution, hence for each specific solution which is expected to be
encountered for actual use, a different order or series will ensue. In a galvanic couple, the
metal higher in the series (or the smaller) represents the anode, and will corrode preferentially
in the environment. Listed below is the latest galvanic table from MIL-STD-889 where the
materials have been numbered for discussion of characteristics. However, for any
combination of dissimilar metals, the metal with the lower number will act as an anode and
will corrode preferentially.

Active (Anodic)

1. Magnesium
2. Mg alloy AZ- 31B
3. Mg alloy HK-31A
4. Zinc (hot-dip, die cast, or plated)
5. Beryllium (hot pressed)
6. Al 7072 clad on 7075
7. Al 2014-T3
8. Al 1160-H14
9. Al 7079-T6
10. Cadmium (plated)
11. Uranium
12. Al 218 (die cast)
13. Al 5052-0
14. Al 5052-H12
15. Al 5456-0, H353
16. Al 5052-H32
17. Al 1100-0
18. Al 3003-H25
19. Al 6061-T6
20. Al A360 (die cast)
21. Al 7075- T6
22. Al 6061-0
23. Indium
24. Al 2014-0
25. Al 2024-T4
26. Al 5052-H16
27. Tin (plated)
28. Stainless steel 430 (active)
29. Lead
30. Steel 1010
31. Iron (cast)
32. Stainless steel 410 (active)
33. Copper (plated, cast, or wrought)
34. Nickel (plated)
35. Chromium (Plated)
36. Tantalum
37. AM350 (active)
38. Stainless steel 310 (active)
39. Stainless steel 301 (active)
40. Stainless steel 304 (active)
41. Stainless steel 430 (active)
42. Stainless steel 410 (active)
43. Stainless steel 17-7PH (active)
44. Tungsten
45. Niobium (columbium) 1% Zr
46. Brass, Yellow, 268
47. Uranium 8% Mo
48. Brass, Naval, 464
49. Yellow Brass
50. Muntz Metal 280
51. Brass (plated)
52. Nickel-silver (18% Ni)
53. Stainless steel 316L (active)
54. Bronze 220
55. Copper 110
56. Red Brass
57. Stainless steel 347 (active)
58. Molybdenum, Commercial pure
59. Copper-nickel 715
60. Admiralty brass
61. Stainless steel 202 (active)
62. Bronze, Phosphor 534 (B-1)
63. Monel 400
64. Stainless steel 201 (active)
65. Carpenter 20 (active)
 66. Stainless steel 321 (active)
67. Stainless steel 316 (active)
68. Stainless steel 309 (active)
69. Stainless steel 17-7PH (passive)
70. Silicone Bronze 655
71. Stainless steel 304 (passive)
72. Stainless steel 301 (passive)
73. Stainless steel 321 (passive)
74. Stainless steel 201 (passive)
75. Stainless steel 286 (passive)
76. Stainless steel 316L (passive)
77. AM355 (active)
78. Stainless steel 202 (passive)
79. Carpenter 20 (passive)
80. AM355 (passive)
81. A286 (passive)
82. Titanium 5A1, 2.5 Sn
83. Titanium 13V, 11Cr, 3Al (annealed)
84. Titanium 6Al, 4V (solution treated and aged)
85. Titanium 6Al, 4V (anneal)
86. Titanium 8Mn
87. Titanium 13V, 11Cr 3Al (solution heat treated and aged)
88. Titanium 75A
89. AM350 (passive)
90. Silver
91. Gold
92. Graphite

End - Noble (Less Active, Cathodic)

Galvanic Compatibility
Often when design requires that dissimilar metals come in contact, the galvanic compatibility
is managed by finishes and plating. The finishing and plating selected facilitate the dissimilar
materials being in contact and protect the base materials from corrosion.

For harsh environments, such as outdoors, high humidity, and salt environments fall
into this category. Typically there should be not more than 0.15 V difference in the
"Anodic Index". For example; gold - silver would have a difference of 0.15V being
acceptable.
For normal environments, such as storage in warehouses or non-temperature and
humidity controlled environments. Typically there should not be more than 0.25 V
difference in the "Anodic Index".
For controlled environments, such that are temperature and humidity controlled, 0.50
V can be tolerated. Caution should be maintained when deciding for this application
as humidity and temperature do vary from regions.
Anodic Index

Metallurgy

Gold, solid and plated, Gold-platinum alloy 0.00

Rhodium plated on silver-plated copper 0.05

Silver, solid or plated; monel metal. High nickel-copper alloys 0.15

Nickel, solid or plated, titanium an s alloys, Monel 0.30

Copper, solid or plated; low brasses or bronzes; silver solder; German silvery high copper-
nickel alloys; nickel-chromium alloys 0.35

Brass and bronzes 0.40

High brasses and bronzes 0.45
18% chromium type corrosion-resistant steels 0.50

Chromium plated; tin plated; 12% chromium type corrosion-resistant steels 0.60

Tin-plate; tin-lead solder 0.65

Lead, solid or plated; high lead alloys 0.70

Aluminium, wrought alloys of the 2000 Series 0.75

Iron, wrought, gray or malleable, plain carbon and low alloy steels 0.85

Aluminium, wrought alloys other than 2000 Series aluminium, cast alloys of the silicon type
0.90

Aluminium, cast alloys other than silicon type, cadmium, plated and chromate 0.95

Hot-dip-zinc plate; galvanized steel 1.20

Zinc, wrought; zinc-base die-casting alloys; zinc plated 1.25

Magnesium & magnesium-base alloys, cast or wrought 1.75

Beryllium

Galvanic Series in Seawater

A galvanic series has been drawn up for metals and alloys in seawater, which shows their
relative nobility. The series is based on corrosion potential measurements in seawater. The
relative position of the materials can change in other environments. The further apart the
materials are in this series, the higher the risk of galvanic corrosion.
Most cathodic, noble, or resistant to corrosion

Platinum
Gold
Graphite
Titanium
Silver
Chlorimet 3
Hastelloy C

1. 18-8 Mo stainless steel (passive)

2. 18-8 stainless steel (passive)
3. Chromium steel >11 % Cr (passive)
4. Inconel (passive)
5. Nickel (passive)
6. Silver solder
7. Monel
8. Bronzes
9. Copper
10. Brasses

Chlorimet 2
Hastelloy B
Inconel (active)
Nickel (active)
Tin
Lead
Lead-tin solders
18-8 Mo stainless steel (active)
8-8 stainless steel (active)
Ni-resist
Chromium steel >11 % Cr (active)

1. Cast iron
2. Steel or iron
3. 024 aluminum
4. Cadmium
5. Commercially pure aluminium
6. Zinc
7. Magnesium and its alloys

Most anodic or easy to corrode