Metals dissimilar-metal corrosion

Finally, mechanical joints, e.g. nuts, bolts, rivets etc., are still important joining methods for which attention must be given to compatibility to avoid dissimilar metal corrosion problems and crevice corrosion " . ... 

Dissimilar-metal corrosion can occur even if the two metals are not initially in direct contact. For example, in homes where copper tubing is used for plumbing, there is always a small amount of dissolved Cu2+ in the water. When this water encounters steel piping or a chrome-plated bathroom sink drain, the more-noble copper will plate out on the other metal, producing a new metals-in-contact corrosion cell. In the case of chrome bathroom sink fittings, this leads to the formation of Cr3+ salts which precipitate as greenish stains. 

Formation of a Galvanic Cell. When a metal or alloy is electrically coupled to another metal or conducting nonmetal in the same electrolyte, a galvanic cell is created. The electromotive force and current of the galvanic cell depend on the properties of the electrolyte and polarization characteristics of anodic and cathodic reactions. The term galvanic corrosion has been employed to identify the corrosion caused by the contact between two metals or conductors with different potentials. It is also called dissimilar metallic corrosion or bimetallic corrosion where metal is the conductor material. 

Although corrosion engineers are well aware of the mechanism and the detrimental effects of galvanic (dissimilar metal) corrosion, it would seem necessary to make some designers, architects and engineers in other disciplines aware of this very damaging form of corrosion. 

Figure 9.16 Dissimilar metal corrosion of a steel rivet in contact with copper and an electrolyte (a) before and (b) after corrosion...

Two different metals that are connected and immersed in an electrolyte form an electrochemical cell. If a current is allowed to flow, one metal will be consumed and one will remain the same or be increased in some way. These processes lead to dissimilar metal corrosion. In order for dissimilar metal corrosion to occur, it is necessary to have an anode, a cathode, an electrolyte and a connection from anode to cathode. The anode component corrodes whereas the cathode remains unattacked. The tendency for such reactions to take place spontaneously can be judged from the electrochemical series. Three examples follow. 

During dissimilar metal corrosion, the metal that corrodes is ... 

Mansfeld F, Hengstenberg DH, Kenkel JV. Galvanic corrosion of aluminium alloys I. Effect of dissimilar metal. Corrosion, 30, 1974 343-353. 

Galvanic corrosion of a metal occurs as a result of electrical contact with a more noble conductor in a corrosive electrolyte. It is often called "dissimilar metal corrosion. Galvanic corrosion can often be avoided by disconnecting the point of electrical contact. In cases where electrical isolation is not possible, proper materia] selection can help minimize the effect. 

Galvanic corrosion (also called "dissimilar metal corrosion" or wrongly "electrolysis") refers to corrosion damage induced when two dissimilar materials are coupled in a corrosive electrolyte. In a bimetallic couple, the less noble material becomes the anode and tends to corrode at an accelerated rate, compared with the uncoupled condition and the more noble material will act as the cathode in the corrosion cell. 

The surface of a metallic object can be easily reacted in normal atmospheres making it behave quite differently from a piece of unreacted metal, often resulting in a situation resembling dissimilar metal corrosion. A film may be formed which is invisible, actually only a few molecules in thickness, but which may have a potential as much as 0.3 V different from the unfilmed metal. Naturally, such a potential difference is enough to create an active corrosion cell. Steels in soil have a tendency to film with time. "Old" steel, that is, steel which has been in the ground for several years may then become cathodic with respect to "new" steel, even when the two are identical in bulk composition (Fig. 7.37). It is thus strictly a surface phenomenon [21]. 

Metalhc coating may be applied to non-metals to provide a conductive surface. Although some problems (e.g. dissimilar metals corrosion) are thereby minimized or obviated, other corrosion reactions of the metal coating should be considered in the same manner as for plated or solid metals. 

FlOiei Evaluation of techniques for assessing corrosion cracking In dissimilar metal welds Dr D.R. Tice AEA Technology... 

This type of corrosive attack occurs when dissimilar metals (i.e., with a different are in direct electrical... 

Galvanic Corrosion. Galvanic corrosion occurs when two dissimilar metals are in contact in a solution. The contact must be good enough to conduct electricity, and both metals must be exposed to the solution. The driving force for galvanic corrosion is the electric potential difference that develops between two metals. This difference increases as the distance between the metals in the galvanic series increases. 

Copper alloys often show only weak crevice corrosion. This is especially the case if the copper alloy is coupled to a less noble alloy such as steel. The corrosion of the steel is stimulated by the galvanic effect caused by the coupling of dissimilar metals. Hence, the sacrificial corrosion of the steel protects the copper alloy (Fig. 2.9). See Chap. 16, Galvanic Corrosion. ... 

Corrosion tests of metals under static conditions reveal nothing relating to erosion-corrosion susceptibilities. It is entirely possible that a metal tested under static conditions will fail in service when sufficient fluid velocity produces erosion-corrosion. Similarly, it has been observed that galvanic corrosion between coupled, dissimilar metals may be accelerated or even initiated under flow conditions when little or no galvanic corrosion is observed under static conditions (see Chap. 16, Galvanic Corrosion ). 

Galvanic corrosion typically involves two or more dissimilar metals. It should be recognized, however, that sufficient variation in environmental and physical parameters such as fluid chemistry, temperature (see Case History 16.3), flow velocity, and even variations in degrees of metal cold work can induce a flow of corrosion current even within the same metal. 

Most galvanic corrosion processes are sensitive to the relatively exposed areas of the noble (cathode) and active (anode) metals. The corrosion rate of the active metal is proportional to the area of exposed noble metal divided by the area of exposed active metal. A favorable area ratio (large anode, small cathode) can permit the coupling of dissimilar metals. An unfavorable area ratio (large cathode, small anode) of the same two metals in the same environment can be costly. 

The corrosion voltages of Fig. 23.3 also tell you what will happen when two dissimilar metals are joined together and immersed in water. If copper is joined to zinc, for instance, the zinc has a larger corrosion voltage than the copper. The zinc therefore becomes the anode, and is attacked the copper becomes the cathode, where the oxygen reaction takes place, and it is unattacked. Such couples of dissimilar metals can be dangerous the attack at the anode is sometimes very rapid, as we shall see in the next chapter. 

Galvanic corrosion results when two dissimilar metals are in contact, thus forming a path for the transfer of electrons. The contact may be in the form of a direct connection (e.g., a steel union joining two lengths of copper... 

---