Tech Beat

A sacrificial anode
An electronic sensor alerts users when a sacrificial anode
fails and needs replacement.

O ne of the key elements in the corrosion process is the gradual deterioration

of the anode as metal is oxidized. If the corrosion process continues uninter-
rupted, then eventually the entire metal anode will be consumed.
Most of the corrosion problems that we deal with in the lubricant industry in-
volve iron. One approach that slows down corrosion is to use a sacrificial anode
composed of a metal different from iron.
A better understanding of the function of a sacrificial anode can be found in re-
membering the electromotive series, which lists metals in order of how easily they
can be oxidized. Minimization of the oxidation of iron can be realized if a second
metal is introduced that will oxidize more readily than iron. Examples include
aluminum and zinc.
Key concepts Therefore, introduction of a second metal such as aluminum with iron will alter
the electrochemical process so that the aluminum will eventually be consumed
• Corrosion of steel over time instead of iron. In this fashion, aluminum assumes the role of a sacrificial
surfaces can be reduced anode.
through the use of a
second metal that can Sacrificial anodes come in differing diameters,
be more readily oxidized
and functions as a
so the use of a thicker rod can delay the failure
sacrificial anode. of a water heater. Use of more than one
• A wear indicator or an sacrificial anode can also delay the process.
electronic sensor can
A key application for sacrificial anodes is in water heaters. Eric Cytrynowicz,
monitor the consumption
director of marketing at Performance Metal Products in Bechtelsville, Pa., says, “A
of a sacrificial mode. sacrificial anode is the backbone in the life of a water heater.”
Water heaters are prepared by fusing glass to a steel surface at 870 C, giving an
• Applications for inner lining of an enameled porcelain referred to as a glass lining. However, like
sacrificial anodes the glass interior of a thermos bottle, this lining can be fractured. Cytrynowicz
include water heaters, explains, “The glass can crack when transporting or shaking the heater, leaving
recreational marine the water with a direct path to the metal. With this exposure, the steel surface will
eventually wear away reducing the operating life of the water heater, unless a sac-
products, pipelines rificial anode is used.”
and underground A sacrificial anode will last on average between two and six years, according to
storage tanks. Cytrynowicz. Once the sacrificial anode is consumed, the water heater might not
last more than two years. In fact, Cytrynowicz indicates that, depending on the
water, the heater and the usage, the water heater may fail as soon as a few months
after the sacrificial anode is used up.
A number of factors influence how long the sacrificial anode will last in a water
heater. Cytrynowicz says, “The rate of corrosion will double for every 10 C increase
in temperature. For an average water heater, the temperature will climb from 4 C
to 55 C every time the unit is used. This increase can lead to a tenfold increase in
the rate of corrosion.”
Water hardness also plays a role as higher levels of calcium and magnesium ions

6 • NOVEMBER 2010 TRIBOLOGY & LUBRICATION TECHNOLOGY WWW.STLE.ORG

 ‘Most sacrificial anodes used in residential applications are prepared
with an alloy containing 94%-96% magnesium.’

accelerate corrosion. But Cytrynowicz maintains that soft- The sacrificial anodes can be attached to the hull, drives
ened water can be a problem, too. He says, “Under softened and other metal components in recreational marine boats.
water conditions, the presence of extra salts in the water will The indicator is composed of an inert plastic resin
accelerate the corrosion of the that does not react with the steel
steel surface.” surface or the metal used to pre-
Sacrificial anodes come in pare the sacrificial anode. Typi-
differing diameters, so the use cally, polypropylene is used.
of a thicker rod can delay the Another version includes an
failure of a water heater. Use of electronic sensor that can either be
more than one sacrificial anode hooked up to a monitoring box or
also can delay the process. send a wireless signal to a specific
Aluminum, magnesium site on the Internet. The sensor
and zinc are the typical metals can trigger a visual signal and send
used in sacrificial anodes. Cy- out a beeping noise when the sac-
trynowicz says, “Most sacrifi- rificial anode needs to be replaced.
cial anodes used in residential Figure 3 shows an image of a
applications are prepared with standard water heater sacrificial
an alloy containing 94%-96% anode to the right of one contain-
magnesium. An aluminum/zinc ing an electronic sensor.
alloy is employed in those ap- Cytrynowicz indicates that the
Figure 3 | Use of an electronic sensor in a sacrificial
plications, which involve water probe is placed in the center of
anode (shown at left) enables the user to determine
of inferior quality.” when it is nearly depleted and should be replaced. the anode but not too close to the
Once a sacrificial anode is When used in a water heater, the standard sacrifi- middle. He says, “We conducted a
consumed, it is only a matter cial anode (shown on right) will fail without warning, series of calculations and trials to
of time before the water heater leading to water leakage. (Courtesy of Performance determine where to best position
fails. Cytrynowicz says, “The Metal Products) the probe to maximize the life of
only warning for a user is the the probe.”
presence of water on the floor.” Sacrificial anodes are used in
Replacement of a sacrificial anode is recommended to other applications such as pipelines and underground stor-
prevent water heater failure. The problem is when to install a age tanks. In addition, sacrificial anodes are used to prevent
second anode. Cytrynowicz indicates that a sacrificial anode corrosion in the lock gates of canals and other waterways.
needs to be removed when it has been depleted by 50%-60%. Cytrynowicz indicates that his company is also looking
The challenge is to figure out when that occurs in order to at other applications for sacrificial anodes. He says, “We are
maximize the operating life of the sacrificial anode, particu- currently using the anodes in fire engine pumps and are ex-
larly because it is inside the water heater and cannot be seen ploring the possibility of using these sensors in fire suppres-
by the user. sion pumps used in hotels and in marine vessels.”
A technology needs to be developed that will alert the Further information can be found in a recent U.S. Patent1
user about when to replace the sacrificial anode. Such a tech- or by contacting Cytrynowicz at e.cytrynowicz@perfor-
nology has not been available until now. mancemetals.com.

ELECTRONIC SENSOR REFERENCE

Performance Metal Products has developed several ap-
proaches to inform the user that the sacrificial anode is due
to fail and needs to be replaced. Cytrynowicz says, “In the
recreational marine products, we have embedded a wear in-
dicator that is brightly colored orange into the sacrificial an-
ode. This is at a specific depth from a surface of the sacrificial
anode and will be easily seen by the user. The orange-colored
indicator does not become visible to the end-user until the
sacrificial anode has lost between 60% and 70% of its metal.”
1. Wigg, M., Leipert, H., Elder, J. and Dixon, K. (2005), “Wear
Indicator for Sacrificial Anode,” U.S. Patent 6,932,l891 B2.
Neil Canter heads his own consulting company,
Chemical Solutions, in Willow Grove, Pa.
Ideas for Tech Beat items can be submitted to
him at neilcanter@comcast.net.

WWW.STLE.ORG TRIBOLOGY & LUBRICATION TECHNOLOGY NOVEMBER 2010 • 7