Galvanic and Corrosion Compatibility Chart - Engineers Edge

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Galvanic Compatibility (Corrosion)

Quality engineering and design requires an understanding of material compatibility. Galvanic corrosion
(some times called dissimilar metal corrosion) is the process by which the materials in contact with each
other oxidizes or corrodes.

There are three conditions that must exist for galvanic corrosion to occur. First there must be two
electrochemically dissimilar metals present. Second, there must be an electrically conductive path between
the two metals. And third, there must be a conductive path for the metal ions to move from the more
anodic metal to the more cathodic metal. If any one of these three conditions does not exist, galvanic
corrosion will not occur. Often when design requires that dissimilar metals come in contact, the galvanic
compatibility is managed by finishes and plating. The finishing and plating selected facilitate the dissimilar
materials being in contact and protect the base materials from corrosion.

For harsh environments, such as outdoors, high humidity, and salt environments fall into this category.
Typically there should be not more than 0.15 V difference in the "Anodic Index". For example; gold – silver
would have a difference of 0.15V being acceptable.

For normal environments, such as storage in warehouses or non-temperature and humidity controlled
environments. Typically there should not be more than 0.25 V difference in the "Anodic Index".

For controlled environments, such that are temperature and humidity controlled, 0.50 V can be tolerated.
Caution should be maintained when deciding for this application as humidity and temperature do vary from
regions

METALLURGICAL CATEGORY ANODIC INDEX (V)

... metal ions move to the more cathodic metal Cathodic - Protected
Gold, solid and plated, Gold-platinum alloy 0.00
Rhodium plated on silver-plated copper 0.05
Silver, solid or plated; monel metal. High nickel-copper alloys 0.15
Nickel, solid or plated, titanium an s alloys, Monel 0.30
Copper, solid or plated; low brasses or bronzes; silver solder; 0.35
German silvery high copper-nickel alloys; nickel-chromium alloys
Brass and bronzes 0.40
High brasses and bronzes 0.45
18% chromium type corrosion-resistant steels 0.50
Chromium plated; tin plated; 12% chromium type corrosion-resistant steels 0.60
Tin-plate; tin-lead solder 0.65
Lead, solid or plated; high lead alloys 0.70
Aluminum, wrought alloys of the 2000 Series 0.75
Iron, wrought, gray or malleable, plain carbon and low alloy steels 0.85
Aluminum, wrought alloys other than 2000 Series aluminum, 0.90
cast alloys of the silicon type
Aluminum, cast alloys other than silicon type, cadmium, plated and chromate 0.95
Hot-dip-zinc plate; galvanized steel 1.20
Zinc, wrought; zinc-base die-casting alloys; zinc plated 1.25
Magnesium & magnesium-base alloys, cast or wrought 1.75
Beryllium 1.85
... metal ions move from the more anodic metal Anodic - Corroded
Corrosion Definition

Corrosion is the deterioration of a material due to interaction with its environment. It is the process in
which metallic atoms leave the metal or form compounds in the presence of water and gases. Metal atoms
are removed from a structural element until it fails, or oxides build up inside a pipe until it is plugged. All
metals and alloys are subject to corrosion. Even the noble metals, such as gold, are subject to corrosive
attack in some environments.

The corrosion of metals is a natural process. Most metals are not thermodynamically stable in the metallic
form; they want to corrode and revert to the more stable forms that are normally found in ores, such as
oxides. Corrosion is of primary concern in engineering and design. Corrosion occurs in every metal subject
to it. Even though this corrosion cannot be eliminated, it can be controlled.

Corrosion Overview

General corrosion involving water and steel generally results from chemical action where the steel surface
oxidizes, forming iron oxide (rust). Many of the systems and components in the plant are made from iron.

Some standard methods associated with material selection that protect against general corrosion
include:The use of corrosion-resistant materials such as stainless steel and nickel, chromium, and
molybdenum alloys. (Keep in mind that the corrosion is electrochemical by nature, and the corrosion
resistance of the stainless steels results from surface oxide films that interfere with the electrochemical
process.)

The use of protective coatings such as paints and epoxies. The application of metallic and nonmetallic
coatings or linings to the surface which protects against corrosion, but allows the material to retain its
structural strength (for example, a carbon steel pressure vessel with stainless steel cladding as a liner).

Localized Corrosion

Localized corrosion is defined as the selective removal of metal by corrosion at small areas or zones on a
metal surface in contact with a corrosive environment, usually a liquid. It usually takes place when small
local sites are attacked at a much higher rate than the rest of the original surface.

Localized corrosion takes place when corrosion works with other destructive processes such as stress,
fatigue, erosion, and other forms of chemical attack. Localized corrosion mechanisms can cause more
damage than any one of those destructive processes individually. There are many different types of
localized corrosion. Pitting, stress corrosion cracking, chloride stress corrosion, caustic stress corrosion,
primary side stress corrosion, heat exchanger tube denting, wastage, and intergranular attack corrosion.

Galvanic Corrosion

Galvanic corrosion occurs when two dissimilar metals with different potentials are placed in electrical contact
in an electrolyte. It may also take place with one metal with heterogeneities (dissimilarities) (for example,
impurity inclusions, grains of different sizes, difference in composition of grains, or differences in mechanical
stress). A difference in electrical potential exists between the different metals and serves as the driving
force for electrical current flow through the corrodant or electrolyte.

This current results in corrosion of one of the metals. The larger the potential difference, the greater the
probability of galvanic corrosion. Galvanic corrosion only causes deterioration of one of the metals. The
less resistant, more active one becomes the anodic (negative) corrosion site. The stronger, more noble one
is cathodic (positive) and protected.
If there were no electrical contact, the two metals would be uniformly attacked by the corrosive medium.
This would then be called general corrosion.

For any particular medium, a list can be made arranging metals sequentially from most active, or least
noble, to passive, or most noble. See Galvanic Compatibility for design applicability.

Galvanic corrosion is of particular concern in design and material selection. Material selection is important
because different metals come into contact with each other and may form galvanic cells. Design is
important to minimize differing flow conditions and resultant areas of corrosion buildup.

In some instances, galvanic corrosion can be helpful in some applications. For example, if pieces of zinc are
attached to the bottom of a steel water tank, the zinc will become the anode, and it will corrode. The steel
in the tank becomes the cathode, and it will not be effected by the corrosion. This technique is known as
cathodic protection. The metal to be protected is forced to become a cathode, and it will corrode at a much
slower rate than the other metal, which is used as a sacrificial anode.

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