Bimetallic corrosion corrosive atmospheres

General corrosion is the most common form of corrosion. This can be uniform (even), quasi-uniform, or uneven. General corrosion accounts for the greatest loss of metal or material. Electrochemical general corrosion in aqueous media can include galvanic or bimetallic corrosion, atmospheric corrosion, stray current dissolution, and biological corrosion (Table 1.1). 

The classification given in Table 1.2 is based on the various forms that corrosion may take, but the terminology used in describing corrosion phenomena frequently places emphasis on the environment or cause of attack rather than the form of attack. Thus the broad classification of corrosion reactions into wet or dry is now generally accepted, and the nature of the process is frequently made more specific by the use of an adjective that indicates type or environment, e.g. concentration—cell corrosion, crevice corrosion, bimetallic corrosion and atmospheric corrosion. 

There are many special factors controlling atmospheric bimetallic corrosion that entitle it to separate treatment. The electrolyte in atmospheric corrosion consists of a thin condensed film of moisture containing any soluble contaminants in the atmosphere such as acid fumes from industrial atmospheres and chlorides from marine atmospheres. This type of electrolyte has two characteristics which are summarised in a paper by Rosenfel d . 

Further information on atmospheric bimetallic corrosion can be found in References... 

Bimetallic corrosion in atmospheres is confined to the area of the less noble metal in the vicinity of the bimetallic joint, owing to the high electrolytic resistance of the condensed electrolyte film. Electrolytic resistance considerations limit the effective anodic and cathodic areas to approximately equal size and therefore prevent alleviation of atmospheric galvanic corrosion through strict application of the catchment area principle. 

Kucera, V. and Mattson, E., Atmospheric Corrosion of Bimetallic Structures, ex Atmospheric Corrosion, 561, J. Wiley and Sons, (1982)... 

Bimetallic corrosion is more severe under immersed conditions than in the atmosphere. In the latter, attack occurs only when the bimetallic contact is wet this depends on many factors, such as the presence or retention of moisture in crevices, the effectiveness of drainage, and the speed of evaporation. The relative size of the areas of the metals that remain wet in the vicinity... 

When considering zinc-aluminum alloys, the surface oxide film normally present is likely to reduce any corrosion current. The risk of bimetallic corrosion is small in atmospheric exposure trials by Noranda have been in progress since 1984 on ZA alloys coupled to other common metals. No visual effects were noted at the 5-year examination (Barmhurst and Belisle, 1992). A zinc-25% aluminum-0.05% magnesium alloy coupled to other materials and exposed on the Noranda Research Center roof showed pitting attack on the zinc-based material (but only up to 0.38 mm deep in 10 years) when joined to copper, brass, or steel, but less when joined to stainless steel or lead and least when joined to aluminum. 

Additional corrosion may occur where the supply of oxygen at interfaces between joined components is limited. This is not bimetallic corrosion, but its effect at bimetallic joints can be as detrimental as true bimetallic corrosion. However, no crevice corrosion occurred in couples of zinc-aluminum alloys and polyethylene in 10-year atmosphere tests (Noranda, personal communication) nor around nylon bolt heads. Jointing compounds are useful in preventing crevice corrosion as well as bimetallic corrosion. Also, stressed parts of the surface tend to be anodic to unstressed parts, but this effect is not usually of practical significance with zinc and zinc-coated steel. 

Oxidation and tarnishing active dissolution in acids anodic oxidation and passivity chemical and electrochemical polishing atmospheric and immersed corrosion in certain cases Crevice corrosion filiform corrosion deposit attack bimetallic corrosion intergranular corrosion weld decay... 

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