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 Galvanic Corrosion

• A Galvanic cell is formed when two dissimilar

metals are connected electrically while both are
immersed in a solution electrolyte. The more
active metals or alloys of the two is corroded
preferentially by galvanic corrosion.
• Important factors in galvanic corrosion
– relative areas of anode and cathode
– difference in potential between anode and cathode
– effect of anodic polarization on anode (some may
passivate)
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 Which is better?

Brass bolt in a steel structure Steel bolt in a brass structure

Small brass cathode Small steel anode

will cause small
increase in corrosion of
steel structure. Bolt
will be protected from
corrosion by coupling
to steel
will suffer large
increase in corrosion
due to coupling with
brass structure.
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• Galvanic corrosion is due to a potential
Galvanic corrosion
difference between two different metals
connected through a circuit for current flow
to occur from more active metal (more
negative potential) to the more noble metal
(more positive potential).

• Galvanic coupling is a galvanic cell in which

the anode is the less corrosion resistant
metal than the cathode.

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 Galvanic corrosion can be predicted by using the
electromotive force (emf) or standard potential
series for metal reduction.

 In selecting two metals or two alloys for a galvanic

coupling, both metals should have similar potentials
or be close to each other in the series in order to
suppress galvanic corrosion.

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Galvanic coupling can be used for cathodic
protection purposes

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 MICROSTRUCTURAL
A EFFECTS
mechanically deformed metal or alloy
can experience galvanic corrosion due to
differences in atomic plane distortion and a
high dislocation density

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• Improper heat treatment can cause
nonuniform microstructure and therefore,
galvanic-phase corrosion is enhanced in
corrosive media.

• Galvanic corrosion can occur in a

polycrystalline alloys, such as pearlitic steels,
due to differences in microstructural phases.

• Pearlite consists of ferrite and cementite -----

galvanic microcells between ferrite (anode )
and cementite (cathode) are generated.

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 Anodic/cathodic electrodes

Anodic/cathodic phases at the

microstructural level

Differences in the concentration of the

Metal ion
How can galvanic cells form?
Differences in the concentration of
oxygen

Difference in the residual stress levels

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 Different phases (even of the same metal) can form a galvanic couple at the
microstructural level (In steel Cementite is noble as compared to Ferrite)
 Galvanic cell may be set up due to concentration differences of the metal ion in the
electrolyte  A concentration cell
Metal ion deficient  anodic
Metal ion excess  cathodic
 A concentration cell can form due to differences in oxygen concentration
Oxygen deficient region  anodic
O2 + 2H2O + 4e  4OH
Oxygen rich region  cathodic
 A galvanic cell can form due to different residual stresses in the same metal
Stressed region more active  anodic
Stress free region  cathodic

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Zero Resistance Ammeter (ZRA)
A zero resistance ammeter (ZRA) is a current to voltage converter
that produces a voltage output proportional to the current flowing
between its input terminals while imposing a 'zero' voltage drop to the
external circuit.

In corrosion test a ZRA is typically used to measure the galvanic

coupling current between two dissimilar electrodes.

An interesting application is when the coupling current between two

nominally identical electrodes is measured. If both electrodes were
identical then very little coupling current would flow.

In real situations these electrodes will be slightly different, one

being more anodic or cathodic than the other and a small coupling
current will exist.
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 Many users like the single function Zero Resistance
Ammeter. It is very simple to use and ideal for testing
simple galvanic couples.

 Having a meter on the front makes it easy to monitor the

Galvanic Current visually every few hours.

 Perfect for any lab. Its purpose is to measure the galvanic

current flowing between two electrodes, WE1 and WE2,
which act as if they are coupled by a zero resistance wire
and to monitor the potential of the galvanic couple

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 Galvanic Corrosion

• A Galvanic cell is formed when two dissimilar

metals are connected electrically while both are
immersed in a solution electrolyte. The more
active metals or alloys of the two is corroded
preferentially by galvanic corrosion.
• Important factors in galvanic corrosion
– relative areas of anode and cathode
– difference in potential between anode and cathode
– effect of anodic polarization on anode (some may
passivate)
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Galvanic Corrosion in Alloys
• Galvanic corrosion can occur between
different phases in an alloy
• This is especially important when one of
the phases is much more active as a
cathode, e.g.:
– Cu-containing precipitates in aluminium
alloys – initiate pitting corrosion
– Fe and Cu impurities in commercial zinc
cause a large increase in corrosion rate
compared to pure zinc
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 Selective leaching
• Removal of one element from a solid alloy by corrosion process is called selective
leaching, e.g. dezincification, graphitizing, de-aluminizing, de-cobaltification etc.
• Dezincification
– Selective removal of zinc from brass, leaving a red copper color appearance
is example of dezincification
– Dezincification can be either uniform (<15% Zn) and localized (low brasses)
– Uniform attacked is common in acidic environments while localized is found in
neutral and alkaline environments (preferably under stagnant conditions)
• Mechanism:
– Zinc dissolve and cause vacancy in lattice structure
– Under deficient condition of oxygen in a corrosion system
(metal/environment), there is race to get oxygen. More reactive species will
act preferentially
• Prevention
– Reducing environment aggressiveness (oxygen removing)
– Cathodic protection is economical
– Selecting proper material for certain environment
– Alloying additions (Sn, As etc.)

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• De-aluminization is a type of corrosion that consists of the selective
loss of aluminum in aluminum bronzes (Cu-Sn) and nickel-aluminum
bronzes. Massive effects have been observed in crevices on aluminum
bronze where the solution contains some chloride ions.

• The primary concerns with de-aluminization are:

• Adverse effects on the ultimate tensile strength of components

• Potential for non-ductile failure
• Loss of leak tightness
• It is a concern for nuclear power generation facilities that utilize
aluminum-bronze alloy piping and piping components for the
transportation.
• Some aluminum alloys are susceptible to this form of corrosion,
particularly in seawater.

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De-cobaltification
•De-cobaltification is a corrosion process in which cobalt is
selectively leached from cobalt-base alloys.

•It creates problems in the tooling/machining industries where

cobalt is leached by many of the amino alcohols and amine-
based additives found in almost all water-miscible machining
fluids. Cobalt leaching is hazardous to carbide tools as well.

Decobaltification problems:
•Reduced performance and life of the tool
•Health problems in some workers, causing dermatitis and
respiratory problems
•Disposal of contaminated wastewater

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