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Contact - With - Other - EN Galvanic Corrosion PDF
Contact - With - Other - EN Galvanic Corrosion PDF
Electrolyte
Metal 1 Metal 2
Cathode
Anode e-
ISBN 978-2-87997-263-3
Diamant Building · Bd. A. Reyers 80 · 1030 Brussels· Belgium · Tel. +32 2 706 82-67 · Fax -69 · e-mail info@euro-inox.org · www.euro-inox.org Materials and Applications Series, Volume 10
CONTACT WITH OTHER METALLIC MATERIALS
Euro Inox
Acroni
www.acroni.si
British Stainless Steel Association (BSSA)
www.bssa.org.uk
Cedinox
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Centro Inox
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Institut de Développement de l’Inox (I.D.-Inox)
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International Chromium Development Association (ICDA)
www.icdachromium.com
International Molybdenum Association (IMOA)
www.imoa.info
Nickel Institute
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Polska Unia Dystrybutorów Stali (PUDS)
www.puds.pl
SWISS INOX
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Table of contents
Disclaimer
Euro Inox has made every effort to ensure that the infor-
mation presented in this document is technically correct.
However, the reader is advised that the material con-
tained herein is for general information purposes only.
Euro Inox, its members, specifically disclaim any liabili-
ty or responsibility for loss, damage, or injury, resulting
from the use of the information contained in this publi-
cation.
1
CONTACT WITH OTHER METALLIC MATERIALS
1 Introduction
Complex design requirements can make sion potential of the metals in contact; hence
it necessary to combine different metallic there is usually a corrosion hazard for the
materials within the same component. Also, partner material.
chance combinations can often be found, The risk of galvanic corrosion occurring
governed only by the availability of, for in- depends, however, on a multitude of factors.
stance, fasteners or shims. In certain cir- Besides the materials used, environment
cumstances, such mixed-material designs and design are crucial. It is therefore diffi-
can lead to corrosion in one of the partner cult to make a priori judgments about
materials. This phenomenon includes gal- the compatibility of materials. The present
vanic corrosion1, in which two different publication describes the principles of galva-
metals form a galvanic couple. nic corrosion and the main parameters
As a result of the formation of galvanic that allow designers to estimate corrosion
elements, accelerated corrosion of the less risk.
noble material can occur. The latter may then
suffer a corrosion rate far higher than that to
be expected without any contact with the
nobler partner metal. Corrosion-related dam-
age such as unacceptable deterioration of
appearance, leaking tubes or failing fasten-
ers can drastically reduce the service life of
a component and lead to premature re-
1
placement. In most technical applications, Accelerated corrosion of a metal, due to the effect of a corrosion ele-
ment. Other factors include concentration elements, aeration elements
stainless steel has the more positive corro- and active/passive elements.
2
CONTACT WITH OTHER METALLIC MATERIALS
For galvanic corrosion to occur, there naturally occur in the metal in isolation; how-
must be: ever, the corrosive attack on the anode is
• different corrosion potentials of greatly accelerated. In some cases, the for-
the metals within a given system; mation of galvanic elements can lead to cor-
• a conductive connection between the rosion in materials that would otherwise be
two metals; corrosion resistant in the environment in
• an electrically conductive humidity question. This can be the case for passive
film (electrolyte) connecting both materials such as aluminium, which can be
metals locally polarised in a certain environment. In
Figure 1 shows the three prerequisites in such cases, localised corrosion phenomena
graphic form. such as crevice corrosion or pitting corrosion
If galvanic corrosion occurs, the less no- can be observed, which would not have
ble material – the anode – is preferentially occurred without the shift in potential
attacked whilst the more noble material – caused by the formation of galvanic ele-
the cathode – is even protected against ments.
corrosion. In fact, the principle of cathodic
protection is based on sacrificial anodes
providing protection from corrosion.
The contact of two metals with different
potentials in an electrically conductive solu-
tion leads to a flow of electrons from the
anode to the cathode. The electro-chemical
reactions are the same as those that would
Electrolyte
Metal 1 Metal 2
e–
3
CONTACT WITH OTHER METALLIC MATERIALS
Figure 3:
Conditions in which
galvanic corrosion
cannot occur
Coating
Electrolyte Electrolyte Electrolyte Electrolyte
Insulator
(Metal 1 = Anode, Metal 2 = Cathode)
4
CONTACT WITH OTHER METALLIC MATERIALS
According to Faraday’s law, electro-chem- reduced and the shift of potential at the an-
ical corrosion processes are directly related ode is limited, as illustrated in Figure 4.
to charge transfer, i.e. the flow of currents. Measurement of potential at the surface
Currents or current densities are therefore identifies, in the case of an insulated anode,
frequently used to measure corrosion. If the the position of the respective potentials of
conditions for galvanic corrosion are met in cathode and anode, independently of each
principle, the total corrosion current Itot is other. In the transition area, a marked jump
composed of a partial current from self- in potential is observed. If an electrically
corrosion Is (i.e. the part of the corrosion that conductive connection between cathode
is independent of contact with other materi- and anode exists, a low polarisation of the
als) and a partial cell current Iel (i.e. the part anode towards higher values is observed
of the corrosion due to the cell current be-
tween the partner materials (Equation 1).
Iel = DU (Equation 2)
Rel + Rp,a + Rp,c
x
From this equation, inferences can be
drawn concerning the factors that determine
galvanic corrosion. These factors are critical Figure 4:
in determining whether or not metallic cor- in electrolytes with high resistance (such as Influence of electrolyte
rosion will become a technically relevant water films resulting from condensation). In resistance on anode
polarisation
problem. The effects of these factors will the case of electrolyte films of low resistance
therefore be discussed individually. (salt water), a very strong polarisation is
measured. The higher the polarisation, the
higher the corrosion rate of the anode if the
3.1 Electrolyte resistance material is active or the higher the probabil-
ity of reaching critical (corrosion-initiating)
The risk of galvanic corrosion diminishes potential if the material is in its passive state.
with increasing electrolyte resistance. This is Table 1 shows specific conductivity values of
because the reach of the galvanic current is various types of water.
5
CONTACT WITH OTHER METALLIC MATERIALS
6
CONTACT WITH OTHER METALLIC MATERIALS
combination of stainless
20 steel with other metallic
materials such as pain-
15 ted carbon steel does not
typically involve a risk of
galvanic corrosion in
10
such circumstances.
0
Urban Near Coastal Marine
atmosphere steel mill area splash zone
Location
Figure 6:
Corrosion rates of
hot-dip galvanized steel,
with and without contact
with stainless steel, in
different environments
7
CONTACT WITH OTHER METALLIC MATERIALS
The kinetics of electrode reactions are A factor in the calculation of cell current
expressed in Equation 3 by the polarisation density, iel (area-related cell current) is the
resistance values of the anode and the ratio of cathodic (Ac) and anodic (Aa) surface
cathode. Differences in potential as low as areas. It strongly influences the velocity of
100 mV can lead to corrosion, while metals galvanic corrosion (Equation 3).
with considerably higher differences of po-
Ac DU
tential can be joined without difficulty. In iel = · (Equation 3)
Aa Rel + Rp,a + Rp,c
fact, difference of potential provides no in-
formation about the kinetics of galvanic cor- As long as the cathodic surface area (the
rosion. The kinetics of the reaction depend more noble metal of the galvanic couple) is
on the metal. Titanium, for instance, reduces very small in comparison to the anodic sur-
dissolved oxygen much less readily than face area (the less noble metal) no change in
copper. This explains why carbon steel cor- corrosion behaviour is observed. This situa-
rodes more quickly in contact with copper tion is shown in Figure 7.
than with titanium, although the latter has
higher positive potential than copper.
In this context, the formation of corrosion Electrolyte
layers also plays a decisive role. These can
significantly change the potential of a mate- Metal 1 Metal 1
rial and be an obstacle to the anodic and/or
cathodic partial reaction. Metal 2
Figure 7:
As the cathode (metal 2)
is small compared to
the anode (metal 1),
no damage is caused.
8
CONTACT WITH OTHER METALLIC MATERIALS
Figure 9:
Galvanic corrosion
Electrolyte is likely to occur if
the anode (metal 1)
is small and the
Metal 2 Metal 2
cathode (metal 2)
is large
Metal 1
Typical examples can be found when The opposite situation, however, can
stainless steel fasteners are used on alu- cause a problem. If a small anode is sur-
minium or galvanized carbon steel compo- rounded by a large cathode, galvanic corro-
nents. Two practical applications are shown sion may occur, as shown in Figure 9.
in Figure 8. Even in corrosive conditions, this Typical examples of such a situation are
material causes virtually no galvanic corro- shown in Figure 10. In these cases, it is clear
sion. that, under corrosive conditions, the partner
Under atmospheric conditions, it is metal may suffer accelerated corrosion.
sometimes difficult to quantify the active
proportions of anodic and cathodic surfaces.
For a practical evaluation, this may, howev-
er, not be necessary. Normally it is sufficient Figure 11:
to consider the system in general. In materi- To prevent galvanic cor-
al combinations, fasteners should always be rosion, only stainless
steel fasteners should be
made of the more noble material, so the ca-
used on stainless steel
thodic surface is small. panels.
Stainless steel
Galvanized steel
Wood
Stainless steel
Figure 10a, 10b:
Practical examples of
the principle shown in
Figure 9 (galvanized
carbon steel in contact
Galvanized steel with stainless steel, in
a marine atmosphere)
9
CONTACT WITH OTHER METALLIC MATERIALS
Extensive research and practical experi- content, such as 1.4307 or 1.4404. Further
ence are available concerning the corrosion guidance can be found in the relevant litera-
behaviour of material combinations involv- ture, provided the corrosion system is con-
ing stainless steel, under different condi- sidered as a whole.
tions. Some relevant results are shown in Apart from numerical values, experience
Tables 2 to 5. Most results refer to stabi- makes it possible to make some general
lized stainless steel grades with higher car- statements, which will be summarised in the
bon content. In principle, the results are following sections.
transferable to grades with reduced carbon
Table 2: Corrosion rates of various metallic materials in contact with stainless steel
Corrosion rate
Galvanic cell Environment Area ratio
(mm/a)
Table 3: Corrosion rates of ZnCuTi in contact with stainless steel grades 1.4541 and 1.4571 in 0.1 N NaCl (aerated, CO2 saturated,
room temperature) according to DIN 50919
Corrosion rate
Galvanic cell Area ratio
(mm/a)
10
CONTACT WITH OTHER METALLIC MATERIALS
Table 4: Corrosion rates of different metallic materials in contact with various stainless steels in an aqueous NaCl solution with 5 %vol. NaCl at
35 °C, surface ratio 1:1 (DIN 50919)
Table 5: Corrosion rates of different materials in contact with stainless steel grade 1.4439 in the North Sea (field test), duration 1 year
Corrosion rate
Galvanic cell Area ratio
(mm/a)
4.1 Water and sewage treatment as 1.4401, 1.4404 and 1.4571 are corrosion
resistant, if properly fabricated. There are al-
Depending on its composition, the corro- so numerous cases of the successful use of
sive effect of water on stainless steel may grade 1.4301.
vary considerably: deionised water without In drinking water, the risk of galvanic cor-
impurities is not corrosive (except at ex- rosion is moderate. For many years, combi-
tremely high temperatures). Drinking water nations of stainless steel, copper, copper
and water of similar composition contains alloys and red brass have been successfully
moderate concentrations of chloride ions used both for cold-water and hot-water
(max. 250 mg/L, according to the Drinking applications in tubes, couplers and tanks,
Water Directive). In unfavourable circum- without damage from contact corrosion
stances, these can lead to pitting or crevice (Figure 12). While carbon steel can be com-
corrosion and, under the combined influ- bined with stainless steel in low-oxygen
ence of high temperatures and chloride con- water, coupling galvanised steel and alu-
centration, to stress corrosion cracking. In minium alloys risks galvanic corrosion in the
most cases, austenitic CrNiMo grades such latter [2].
11
CONTACT WITH OTHER METALLIC MATERIALS
Figure 12:
In plumbing, combinati-
ons of stainless steel
with copper and copper
alloys such as gun metal
are successfully used.
Zn / galvanized steel – + – o* +*
Al – o/– +* – +*
Cu – – – +* +*
Stainless steel – – – o +
Steel in concrete – – – + +
12
CONTACT WITH OTHER METALLIC MATERIALS
13
CONTACT WITH OTHER METALLIC MATERIALS
Figure 14:
Galvanic corrosion in the
stainless steel fasteners
of a filter basin at a water
treatment installation,
involving activated car-
bon: assembly (left) and
disassembled anchor
screw of 1.4016 stain-
less steel, showing loss
of cross section area
from corrosion (right)
14
CONTACT WITH OTHER METALLIC MATERIALS
Carbon steel /
+* – – +* +*
cast iron
Zn / galvanized steel +* + + o +
Al o/– o + o/– +
Cu – – – + +
Figure 15:
Fastening of a stainless Galvanized steel
steel cover (on a facade
assembly) using galvani-
Red rust
zed screws: the screws
steel corrosion
show white rust and in-
itial discolouration (steel
corrosion) after one year White rust
in urban atmosphere steel corrosion
Stainless steel
Figure 15 shows an example. The upper al combinations. In roof repairs, it is not un-
end of horizontal stainless steel sections in common to join larger surfaces of stainless
a steel and glass facade was covered using steel with other metals. Such combinations
two galvanized screws. Starting from the can also be considered uncritical unless the
crevice between the lid and the screw, these ratio between the stainless steel part and the
show marked white rust formation and even, aluminium or galvanized part significantly
to some extent, corrosion of the base mate- exceeds 1:1.
rial. These phenomena were observed after Figures 17 to 20 show practical examples
only about 12 months of service, which indi- of the risk of galvanic corrosion in the build-
cates that this is not a durable solution. ing envelope being efficiently prevented.
Stainless steel fasteners should be substi-
tuted for the galvanized screws.
In roofing technology – both in new build
and renovation – stainless steel is predomi-
nantly used for fasteners which are in contact
with other metallic materials or materials
with metallic coatings. Due to the favourable
ratio of anodic and cathodic surfaces, there
is generally no corrosion risk in such materi-
16
CONTACT WITH OTHER METALLIC MATERIALS
Figure 17:
Fastening stainless steel
outer panels to a carbon
steel structure on the
Atomium, Brussels
Figure 18:
The stainless steel outer
panel is insulated from
the inner galvanized
steel panel by suitable
joints.
Figure 19:
Fabricating insulated
panels using stainless
steel for the outer shell
and galvanized carbon
steel for the inner shell
Figure 20:
To prevent galvanic
corrosion, the stainless
steel cladding is fastened
to the carbon steel inner
structure in non-humid
areas.
17
CONTACT WITH OTHER METALLIC MATERIALS
Figure 21:
In automotive exhaust
systems, stainless steel
is the normal choice. Figure 22:
The rubber parts of the Stainless steel is in-
fasteners prevent galva- creasingly used for fuel
nic corrosion. tanks. The fasteners
keeping them in place
ensure interruption of
electrical conductivity
at the joint.
18
CONTACT WITH OTHER METALLIC MATERIALS
Figure 23:
Simple insulation techni-
ques make the tram’s
Figure 24:
ferritic stainless steel
In this side wall of a com-
body compatible with the
muter train, the structure
carbon steel chassis.
and outer panels are in
different grades of stain-
less steel. As these have
identical potentials, no
galvanic corrosion can
occur.
Figure 25:
Used for buses and
coaches, stainless steel
(usually a painted ferritic
grade) has proved com-
patible with a carbon
steel chassis.
19
CONTACT WITH OTHER METALLIC MATERIALS
Question:
Can stainless steel rebar be joined with
carbon steel in reinforced concrete?
corrosion, as the free corrosion potentials of Answer:
both partner metals are identical. However, Yes, for carbon steel reinforcement, such
the corrosion resistance of each alloy must a combination does not normally raise cor-
be considered individually. Also the materi- rosion questions, as the corrosion potentials
al with lower corrosion resistance must be are identical. Such a combination can be
20
CONTACT WITH OTHER METALLIC MATERIALS
used to prevent corrosion, when the rein- Figure 28: Given a mini-
Stainless steel
mum coverage of con-
forcement penetrates the concrete or comes Carbon steel
crete and providing the
into contact with tubes. The joint must be carbon steel is in its pas-
well within the concrete, with a minimum sive state, stainless steel
concrete cover of 3 cm. If the carbon steel re- reinforcement can be joi-
ned with carbon steel
bar is in the active state (i.e. it is depassi-
without risk of galvanic
vated, due to the influence of chlorides corrosion.
and/or carbonation), galvanic corrosion is recommended, since the areas most at risk
possible. However, in most cases, this effect are additionally covered.
is much less significant than that of the
inevitable element formation between active Question:
and passive carbon steel rebar (galvanic Can stainless steel infill for parapets be
corrosion through an active/passive ele- combined with carbon steel posts?
ment), since the cathodic efficiency of stain- Answer:
less steel is much lower than of carbon steel If the design prevents an electrolyte (for
(Figure 28). instance rain or melting snow) forming over
an extended period, such a direct contact is
Question: acceptable. Otherwise plastic bushes should
Are washers made of insulating polymers be used.
effective for preventing contact corrosion in
mechanical joints?
Answer:
Although this joint does not interrupt
metallic contact between the materials in the
area of the thread, such washers can be
21
CONTACT WITH OTHER METALLIC MATERIALS
The obvious way to prevent galvanic cor- To reduce the cathodic effect of the stain-
rosion is to select suitably compatible mate- less steel part, it is often sufficient to coat the
rials at design stage. If the materials that stainless steel around the joint (Figure 29).
have to be used could interfere with each The width of the zone to be covered depends
other, protective measures must be taken. on the conductivity of the corrosive environ-
Section 2 provides guidance on the nature of ment. In components exposed to normal
these measures. Figure 3 describes the prac- room atmosphere and rather thin and weak-
tical possibilities: ly conductive electrolyte films, it is often suf-
• Electrical insulation of the compo- ficient to coat an area only a few centimetres
nents (insulators, plastic bushes or wide along the contact line on the stainless
polyamide washers) steel side. In salty liquid films several mil-
• Positioning of the joint in an area not limetres thick, the effective cathode area be-
exposed to humidity comes wider than 10 cm.
• Coating a cathode or an anode and
cathode (either on large surface areas
or locally, near the joint).
It should be noted that just coating the
anode is not a suitable way to prevent gal-
vanic corrosion. Imperfection in the coating
or local damage, which are difficult to avoid
on-site, create a critical corrosion element:
any damage to the coating exposes a small
anode, which can then corrode rapidly.
22
CONTACT WITH OTHER METALLIC MATERIALS
6 Literature
23
CONTACT WITH OTHER METALLIC MATERIALS
24
Stainless Steel in Contact
with Other Metallic Materials
Electrolyte
Metal 1 Metal 2
Cathode
Anode e-
ISBN 978-2-87997-263-3
Diamant Building · Bd. A. Reyers 80 · 1030 Brussels· Belgium · Tel. +32 2 706 82-67 · Fax -69 · e-mail info@euro-inox.org · www.euro-inox.org Materials and Applications Series, Volume 10