Reducing galvanic

To prevent or reduce galvanic corrosion we can employ several techniques. Any one of these techniques may be used either by itself or in combination of two or more of the techniques. These techniques are as follows ... 

Design improvements have played a major role in the development of corrosion resistant vehicles. Areas of entrapment, where salt, poultice and other materials could build up and provide a corrosive environment, have been eliminated to enhance corrosion resistance in vehicles. For example, wheel wells are now designed to have a sloping configuration so that corrosives can be washed or will drain out. Drain holes have been incorporated in areas so that corrosive liquid cannot accumulate. Sealers are used to eliminate crevices and joints where corrosives can build up. And, attempts have been made to reduce galvanic corrosion by avoiding dissimikkr metal contact. 

Because of their low electrical conductivity, adhesives significantly reduce galvanic corrosion between dissimilar metals... 

A great many sealer applications are not visible in a modem automobile body. Low viscosity, rubbery sealers are used in virtually all metal-to-metal body joints prior to spot welding. Many of these materials contain gas-forming chemicals which decompose when heated to give a foamy seal which is able to seal out moisture, air, and dirt. They also reduce galvanic corrosion. 

Corrosion Inhibitors. A water-soluble corrosion inhibitor reduces galvanic action by making the metal passive or by providing an insulating film on the anode, the cathode, or both. A very small amount of chromate, polyphosphate, or silicate added to water creates a water-soluble inhibitor. A slightly soluble inhibitor incorporated into the prime coat of paint may also have a considerable protective influence. Inhibitive pigments in paint primers are successful inhibitors except when they dissolve sufficiently to leave holes in the paint film. Most paint primers contain a partially soluble inhibitive pigment such as zinc chromate, which reacts with the steel... 

Clad transition metal systems provide an interface between two incompatible metals. They not only reduce galvanic corrosion where dissimilar metals are joined, but they also allow welding techniques to be used when direct joining is not possible. Qad metals provide an ideal solution to the materials problem of dual environments. For example, in the application of small battery cans and caps, copper-clad, stainless steel-clad nickel (Cu/SS/Ni) is used where the external nickel layer provides atmospheric corrosion resistance and low contact resistance. The copper layer on the inside provides the electrode contact surface as well as compatible cell chemistry. The stainless steel layer provides strength and resistance to perforation corrosion. 

The use of galvanized or metallized steel washers in contact with the anodic member of the connection reduces galvanic attack on this metal (see Figure 9.30). 

Hard plating is noted for its excellent hardness, wear resistance, and low coefficient of friction. Decorative plating retains its brilliance because air exposure immediately forms a thin, invisible protective oxide film. The chromium is not appHed directiy to the surface of the base metal but rather over a nickel (see Nickel and nickel alloys) plate, which in turn is laid over a copper (qv) plate. Because the chromium plate is not free of cracks, pores, and similar imperfections, the intermediate nickel layer must provide the basic protection. Indeed, optimum performance is obtained when a controlled but high density (40—80 microcrack intersections per linear millimeter) of microcracks is achieved in the chromium lea ding to reduced local galvanic current density at the imperfections and increased cathode polarization. A duplex nickel layer containing small amounts of sulfur is generally used. In addition to... 

When the layer of graphite and corrosion products is impervious to the solution, corrosion wdl cease or slow down. If the layer is porous, corrosion will progress by galvanic behavior between graphite and iron. The rate of this attack will be approximately that for the maximum penetration of steel by pitting. The layer of graphite formed may also be effective in reducing the g vanic action between cast iron and more noble alloys such as bronze used for valve trim and impellers in pumps. 

Elimination. Recall that the critical factors governing galvanic corrosion of welds are the presence of substantial compositional differences within the weld metal and the exposure of such a weld to a sufficiently aggressive environment. If the aggressiveness of the environment cannot be sufficiently reduced, significant compositional differences within the weld metal must be avoided. This requires following proper... 

Galvanic corrosion may also occur by transport of relatively noble metals, either as particulate or as ions, to the surface of an active metal. For example, ions of copper, perhaps resulting from corrosion or erosion-corrosion at an upstream site, may be carried by cooling water to the surfaces of aluminum, steel, or even stainless steel components. If the ions are reduced and deposit on the component surfaces, localized galvanic corrosion may result. 

Consideration of the basic elements characteristic of the galvanic corrosion process, as discussed above, points to the principles of sound preventive techniques. Since a galvanic potential difference is the driving force for corrosion reducing the magnitude of this difference can reduce or prevent galvanic corrosion. 

Aluminum components are sensitive to ions of heavy metals, especially copper. To avoid localized galvanic corrosion of the aluminum by metallic copper reduced from copper ions, care must be exercised to prevent heavy metal ions from entering aluminum components. Note the recommendations under Elimination. ... 

An interesting effect is sometimes observed when cupronickels are galvanically coupled to less noble materials. The corrosion rate of the active metal is increased and the corrosion rate of the cupronickel is diminished, as expected. The diminished corrosion rate of the cupronickel can, however, diminish its fouling resistance since reduced production of copper ions lowers toxicity to copper-ion-sensitive organisms. 

Corrosion of the fasteners occurred due to their galvanic interaction with passive stainless steel. Deterioration was rapid because of the unfavorable area ratio formed by the large areas of stainless steel and the small area of the fasteners, which was further reduced by the incomplete plastic covering overexposed fastener surfaces. 

The quality control of galvanic anodes is reduced mainly to the analytical control of the chemical composition of the alloy, to the quality and coating of the support, to an adequate joint between support and anode material, as well as to restricting the weight and size of the anode. The standards in Refs. 6, 7, 22, 27, 31 refer to magnesium and zinc anodes. Corresponding specifications for aluminum anodes do not exist. In addition, the lowest values of the rest potentials are also given [16]. The analytical data represent the minimum requirements, which are usually exceeded. 

Cathodic protection, complete or partial (stem and bow), is arranged by the distribution of the anodes so that the desired current distribution is maintained correctly in the relevant areas. Galvanic anodes, depending on their dimensions and current output, deliver a certain maximum current which depends on the conductivity. The calculated maximum current from Eq. (6-12) based on the driving voltage and grounding resistance is reduced in practice on working anodes due to film for-... 

---