Galvanic Corrosion

Friedrichshafen, 17.08.2011
OASO Brian Ponstein
AGENDA

01. Overview of Galvanic Corrosion

02. Examples
03. Design Guideline
04. Notes
01. Overview
Galvanic Corrosion or Bimetallic Corrosion
• What is it?
 Galvanic corrosion attacks areas where one metal is in
electrical contact with a different metal of a different electrical
potential in an electrically conducting fluid.

• What causes it?

1. Having different metals far apart in the galvanic series
2. Metals are in electrical contact (metals are either directly
touching each other or touching a different metal)
3. Metals are in an electrically conducting fluid (e.g. Coolant,
water, acid, fuel…)
NOTE: if one of these are missing, galvanic corrosion cannot
happen.
01. Overview Galvanic Corrosion
Galvanic Series
The further apart the 2
metals are, there exists
a greater potential for
galvanic corrosion.

Example:
Aluminum and copper
will have galvanic
corrosion, but copper
and tin are ok.
Cadmium and nickel will
also have galvanic
corrosion which is the
reason they are
commonly used for
batteries (NiCd).
01. Overview
Galvanic Corrosion or Bimetallic Corrosion

A battery with an electrical

circuit is a good example.
There is a carbon rod
suspended in an electrolyte
fluid contained in a zinc
container. Once the zinc and
carbon rod are connected via
an electrical circuit (wire)
current can flow between the
two metals. Once this happens
the zinc will start to corrode. As
soon as there is an electrical
open, corrosion stops.
 01. Overview
Galvanic Corrosion or Bimetallic Corrosion

Metals are not in If both metals are in

contact with each electrolyte fluid and in
other and/or not in the electrical contact, then
electrolyte solution, Galvanic Corrosion is
then Galvanic possible
Corrosion is
impossible
The 2 metals are not
required to be
Example: physically touching
If silicon hoses each other. They only
(electrically insulated) have to allow current
are used to join an to flow between the
aluminum pipe to a two metals via a
cast iron housing different source than
galvanic corrosion the fluid.
cannot hapen.
02
Examples

Hose with high

concentration of
Carbon (not
electrically insulated)

Corrosion

Aluminum Oil Cooler

02
Examples
Aluminum hosing for
coolant on the engine. A
rubber hose containing
high levels of carbon was
used to connect piping to
the radiator.
Corrosion
02
Examples

Household plumbing:
Galvanized or steel pipe
attached to a copper pipe.
Result: Corrosion

Steel pipe
Copper Union
03
Design Guideline
Always use MTU approved Fluids
• Consider aluminum components in external parts
• For instance if the Radiator has aluminum parts then an aluminum
compatible coolant must be used.

Do one or more of the following:

• Use metals close to each other
in the Galvanic series
• (Slide 4)
• Prevent electrical contact
• Insulate dissimilar metals (coatings)
04
Notes
• MTU approved fluids contain corrosion inhibitors to prevent problems of
galvanic corrosion.
o MTU has seen acceptable performance from cooling systems designed
with both aluminum and copper core radiators with their engines.
• A test can be done by checking the voltage of the coolant with ground to
see if a voltage is obtained (below 0.1VDC there shouldn’t be any
problems).
o This is only a simple quick test.
o If a voltage reading is higher than 0.5VDC - a check for loose wiring is
required as there is probably of stray current present.