Journals & Books Register Sign in
Galvanic Corrosion
Galvanic corrosion (dissimilar-metal corrosion) is an electrochemical process in which one metal
corrodes preferentially, when in electrical contact with a different type of metal, and both metals
are immersed in an electrolyte such as water.
From: Shreir's Corrosion, 2010
Learn more about Galvanic Corrosion
TYPES OF CORROSION
Zaki Ahmad, in Principles of Corrosion Engineering and Corrosion
Control, 2006
4.3.6 EXAMPLE OF FAILURES OF GALVANIC
CORROSION
Numerous examples of galvanic corrosion are encountered as it is
one of the most frequently encountered forms of corrosion. The
following are common examples:
(1) Galvanic corrosion of aluminum shielding in buried telephone
cables.
(2) Galvanic corrosion of steel pipe with brass fittings.
(3) Galvanic corrosion of the body of the ship in contact with brass or
bronze propellers.
(4) Galvanic corrosion on a gannet wheel where the steel securing the
bolts is in contact with the magnesium wheel.
(5) Galvanic corrosion between the tubes and the tube sheet in heat
exchangers.
(6) Aluminum conduit buried in steel reinforced concrete.
(7) Galvanic corrosion of steel coated with copper due to the defects
in copper coating.
(8) Galvanic corrosion of the Statue of Liberty.
(9) Galvanic corrosion inside horizontal stabilizers in aircrafts.
Read full chapter
Corrosion of magnesium (Mg) alloys in
engine coolants
G.-L. Song, D.H. StJohn, in Corrosion of Magnesium Alloys, 2011
11.3.3 Galvanic current measurement
Galvanic corrosion within the engine cooling system is one of the
biggest concerns. It is quite possible that a magnesium engine block
has an Al alloy head. The galvanic effect between magnesium alloys
and the aluminium alloy should be evaluated in the laboratory. The
setup shown in Fig. 11.1 is quite simple. Magnesium and aluminium
alloy electrodes are immersed in a beaker of the coolant, face to face
Related terms:
Alloys, Anode, Cathode, Corrosion,
Magnesium, Coatings, Electrolytes,
Materials, Steel, Surfaces
Download as PDF
Intelligent Stannate-Based Coatings of Self-
Healing Functionality for Magnesium
Alloys
Abdel Salam Hamdy Makhlouf, in Intelligent Coatings for Corrosion
Control, 2015
15.3.5 Galvanic corrosion
Galvanic corrosion is an electrochemical action of two dissimilar
metals in the presence of an electrolyte and an electron conductive
path (Figure 15.9). A potential difference usually exists when two
dissimilar metals are in contact. In such case, corrosion of less
resistant metal is increased while corrosion for more resistant metal is
reduced; whereas, more active metal acts as an anode (the one that
will corrode) and more resistant metal acts as a cathode. The further
apart the metals in the galvanic series are (Figure 15.10), the higher
the rate of galvanic corrosion there is. Magnesium alloys have high
susceptibility to galvanic corrosion due to excessive levels of heavy
metal or flux contamination. Severe galvanic corrosion takes place
when magnesium is in contact with less active metals such as Fe, Ni,
or Cu (they have low hydrogen overpotential and act as efficient
cathodes). On the contrary, metals that combine an active corrosion
potential with high hydrogen overpotential such as Al, Zn, Cd, and
Sn, are much less damaging, and, therefore, they are favorable as
alloying elements for magnesium alloys.
There are several factors affecting the rate of galvanic corrosion: (1)
the degree of potential difference between the two metals; (2) the
distance effect, with the greatest attack usually being near the
junction; (3) the area effect, where it is better to have large anodes
and small cathodes; and (4) the corrosiveness of the surrounding
media.
The author’s recent research studies on some rare-earth-containing
magnesium alloys such as AZ91E, EV31A-T6, and Elektron ZE41 Mg-
Zn-rare earth revealed the occurrence of galvanic corrosion between
the inert phase associated with rare-earth metals and active
magnesium matrix. Figure 15.11 shows the formation for rare-earth
phases in Mg matrix and the occurrence of galvanic corrosion at the
interface.
Read full chapter
with a fixed distance (2 cm) between them. The galvanic current
between these two electrodes is then monitored.
Recently, a sandwich-like assembly consisting of aluminium, stainless
steel and magnesium coupons, which simulates a magnesium
engine block with an aluminium head and a steel gasket inserted
between the two alloys, has also been used by Zhang et al. to evaluate
the galvanic corrosion of magnesium in a coolant [9].
Read full chapter
CORROSION PREVENTION BY DESIGN
Zaki Ahmad, in Principles of Corrosion Engineering and Corrosion
Control, 2006
8.6.1 BIMETALLIC CONTACT
Bimetallic corrosion is serious and it occurs when two materials
differing in electrochemical potential are joined together. The
galvanic series is a practical guide for engineers. The position of two
metals or alloys in galvanic series dictates the extent of bimetallic
corrosion. Consider, for instance, aluminum and copper. It can be
observed from the table that aluminum is active to copper in the
galvanic series and hence it would act as anode to copper which
become the cathode due to its relatively more noble position. Joining
the two would, therefore, give rise to bimetallic corrosion. The joining
of two metals and alloys close to each other in the galvanic series
would not cause bimetallic corrosion. The closer together are the
materials in the galvanic series, the less the potential difference (the
driving force for corrosion) and further apart the materials in the
galvanic series the greater would be the potential difference and a
greater driving force for corrosion. The following are the factors
affecting bimetallic corrosion:
a) Difference of potential.
b) A small anodic area to a large cathodic area.
c) Conduction of electrolyte.
d) Deposition of impurities and deposits, such as hygroscopic
particles, sand or salt particles.
e) Contact with insulation materials.
a) Potential Difference
The greater the difference of potential between the two metals, the
greater is the magnitude of bimetallic corrosion. Figure 8.4 shows a
valve from a condensate pipe. The cast iron valve was incorporated in
AISI 304 stainless steel condensate pipe of a copper heat exchanger.
The difference of potential between copper, steel and cast iron caused
bimetallic corrosion.
b) Anode to Cathode Ratio
A small anode area to a large cathode area causes serious bimetallic
corrosion because of a large current density on a smaller anodic area.
Figure 8.5a shows a steel rivet in a copper sheet and Fig. 8.5b shows
copper rivets in a steel sheet. More severe corrosion in the first case is
observed and is concentrated on small anodes (steel rivets).
c) Deposition of Impurities
The deposition of impurities must not be allowed. The deposition of
impurities, as debris cause the formation of differential aeration cells,
and allows the absorption of moisture from the air which leads to
corrosion (Figs 8.6(a) and (b)). The passive surface of steel may be
destroyed by such deposits. The sites under the deposits become the
anodes and the lead to pitting. A significant difference between the
anodes and the cathodes may be observed. Hence, a good design
should not allow the built-up of impurities on the surface. In Figs
8.7(a) and (b) the dirt and impurities cannot be easily removed, hence,
Durability of steel components
strengthened with fiber-reinforced polymer
(FRP) composites
M. Dawood, in Rehabilitation of Metallic Civil Infrastructure Using
Fiber Reinforced Polymer (FRP) Composites, 2014
4.3.1 Fundamental principles
Galvanic corrosion is an electrochemical process that occurs when
electrons can flow freely between two different materials with
sufficiently different electrical potentials. In order for
galvanic corrosion to occur, four factors must be present as illustrated
in Fig. 4.1:
1. two metals (or semi metals) with sufficiently different electrical
potentials to drive a current;
2. an electrical connection between the two materials;
3. an electrolyte bridging the two materials;
4. a sustained reaction at the cathode (in structural applications this
typically requires the presence of dissolved oxygen in the
electrolyte).
Electrical half-cell potential can be defined as the voltage difference
between a given material and a standard reference electrode, such as
hydrogen or calomel. The potential difference between two materials
is, thus, the difference between their respective half-cell potentials.
Some references indicate that in order for two materials to drive a
galvanic current, the electrical potential difference between them
should be at least 100 mV (Vargel, 2004). In the presence of the other
three factors, the material with the lower (more negative) electrical
potential becomes the anode and the material with the higher (more
positive) electrical potential becomes the cathode. When the two
materials are coupled, the anode loses electrons to the cathode and
releases positive ions into the electrolyte. This coupling accelerates
the corrosion rate of the anode and reduces the corrosion rate, or
halts corrosion altogether, of the cathode. Research indicates that the
potential difference between carbon (coated with a thin layer of epoxy)
and steel submerged in different electrolytes is between 500 and
700 mV with the steel being more electronegative (anode) and the
carbon being less electronegative (cathode) (Tavakkolizadeh and
Saadatmanesh, 2001). This electrical potential difference is sufficient
to drive a galvanic current which could accelerate the corrosion of the
steel if the remaining three conditions are met.
For steel structures strengthened with CFRP that are exposed to
environmental factors, the presence of an electrolyte which bridges
the two materials can reasonably be expected. For example, in marine
applications, or for partially submerged structures, the presence of
seawater or fresh water containing dissolved salts or minerals could
provide an appropriate medium for the necessary ion exchange
between the steel and CFRP to occur. Similarly, in bridge applications,
the use of de-icing solutions could provide an electrolytic medium
that would facilitate galvanic corrosion of the steel. In exposed
structures, rainwater ponded on or around structural steel members
or surface moisture could also act as an electrolyte. Therefore, for
CFRP-strengthened structures exposed to environmental factors,
particular care should be taken to minimize the possibility of
galvanic corrosion. Similarly, in some industrial or commercial
structures, such as chemical plants and food-processing plants,
exposure to electrolytes is likely. In contrast, in many interior
applications, such as in schools, office buildings or hospitals,
exposure to electrolytes is minimal and intermittent, if any. As such,
in these applications, the likelihood of galvanic corrosion is inherently
low.
the two designs are poor designs. Impurities or deposits can easily be
removed in the designs shown by Figs 8.7(c) and (d). Figure 8.8
shows good and poor designs against rain.
In automobiles, structural members must be designed to minimize
the retention of water on the surface. Some examples of preferred
orientation and design are shown in Figs 8.9(a) and (b).
d) Wet Atmosphere
If the wet surface is maintained for a longer duration, in particular if
salt particles are present, bimetallic corrosion is aggravated. The
design of components must not allow the retention of a layer of water
on the surface. A smooth polished surface would not allow water
retention. A smooth design of polished surface sloping downwards
would not allow the retention of water layer for longer periods of
time. More examples of good and bad channel designs are shown in
Fig. 8.10.
e) Contact with Wet Insulation Materials
Insulation materials, such as glass wool, glass fibers, polyurethane
foam, do not cause the corrosion of steel in contact with insulation as
long as the insulation material remains dry. Corrosion underneath
insulation, however, assumes significant proportions if the insulation
becomes wet during storage, operation or field erection. Following
are the factors leading to insulation-induced corrosion:
1) Ingress of moisture in the insulation resulting in the leaching of
soluble salts of low pH (about 2–3).
2) Release of chloride ions.
3) Destruction of passivity of steel by chloride ions and initiation of
pits.
4) Weather cycles, such as wet-dry, hot-dry, and damp-warm cycles,
which induce high corrosion rates.
5) Inadequate moisture barriers, because of inadequate spacing of
insulation.
The effect of moisture ingress is shown in Figs 8.11, 8.12 and 8.13
shows the corrosion caused by ingressing of moisture in insulation in
a water heater after six months of service.
Corrosion induced by insulation can be prevented by the following
measures:
1) Eliminating flat horizontal surfaces.
2) Structural designs which trap water (example, H-beams and
channels) (Fig. 8.14).
3) Strict compliance of insulation thickness.
4) Providing an adequate moisture barrier and waterproofing.
5) Addition of sodium silicate as an inhibitor.
An idealized design to prevent insulation-induced corrosion is shown
in Fig. 8.15.
Read full chapter
When electrolytes are present, a sustained cathodic reaction must
proceed in order to sustain the high rate of corrosion of the anodic
material. If a cathodic reaction cannot be sustained, the positive ions
and the electrons that are released from the anode cannot be
consumed at the cathode. Consequently, the rate of corrosion
gradually decreases. In structural applications, the sustained cathodic
reaction typically involves consumption of dissolved oxygen.
Consequently, the likelihood of galvanic corrosion is higher for
structures that are exposed to repeated cycles of wetting and drying
such as in splash zones, around bridges or in structures exposed to
rainwater or melt runoff. In contrast, structures that are permanently
submerged are less likely to experience galvanic corrosion since the
dissolved oxygen necessary to drive the cathodic reaction can be
quickly consumed. Often the structures that are most in need of
repair are those structures that are most susceptible to
galvanic corrosion due to repeated wetting and drying. In these
applications, care must be taken to minimize the likelihood of
galvanic corrosion, for example by preventing an electrical connection
between the steel and the CFRP or by coating the structure, to
maximize the longevity of the intervention.
Read full chapter
Management and Control of Corrosion
C. Frayne, in Shreir's Corrosion, 2010
4.27.7.3 Galvanic Corrosion
Galvanic corrosion (dissimilar-metal corrosion) is an electrochemical
process in which one metal corrodes preferentially, when in electrical
contact with a different type of metal, and both metals are immersed
in an electrolyte such as water. Typically in an industrial process water
system or HVAC system, different metals of construction will be used,
and more often than not they are not dielectrically insulated from
each other, but are connected via a flange, valve, union, or brazed
joint. Thus, when the two or more different types of metal come into
contact with one another (as in the coupling of steel and copper in a
heat-exchanger), a galvanic couple is set up, as the different metals
have different electrode potentials. The electrode potential is the
tendency of a metal to give up electrons and go into solution.
The system water electrolyte provides a means for ion migration,
whereby metallic ions can move from the anode to the cathode. This
leads to the anodic metal corroding more quickly than it otherwise
would; the corrosion of the cathodic metal is retarded even to the
point of stopping. The presence of electrolyte and a conducting path
between the metals may cause corrosion, where otherwise neither
metal alone would have corroded. Also, a single type of metal may
corrode galvanically if the electrolyte varies in composition, forming a
concentration cell.
The rate of galvanic corrosion is strongly influenced by the electrode
potential difference between the dissimilar metals. The galvanic series

Activity and passivity of magnesium (Mg)
and its alloys
E. Ghali, in Corrosion of Magnesium Alloys, 2011
2.5.2 Galvanic corrosion or bimetallic corrosion
Galvanic corrosion or bimetallic corrosion is important to consider
since most of the structural industrial metals and even the metallic
phases in the microstructure alloys create galvanic cells between them
and/or the α Mg anodic phase. However, these secondary particles
which are noble to the Mg matrix, can in certain circumstances enrich
the corrosion product or the passive layer, leading to a decrease or a
control of the corrosion rate. Severe corrosion may occur in neutral
solutions of salts of heavy metals, such as copper, iron and nickel. The
heavy metal, the heavy metal basic salts or both plate out to form
active cathodes on the anodic magnesium surface. Small amounts of
dissolved salts of alkali or alkaline-earth metal (chlorides, bromides,
iodides and sulfates) in water will break the protective film locally and
usually lead to pitting ().
Under conditions where the corrosion product is not continuously
removed or under conditions of high cathodic current density where
the surroundings may become strongly alkaline, both the magnesium
and an amphoteric contacting metal such as aluminum may suffer
severe attack. Such attack destroys compatibility in alloys containing
significant iron contamination. Cathodic corrosion of aluminum is
much less severe in seawater than in NaCl solution because of the
buffering effect in seawater. Aluminum alloys containing appreciable
magnesium, such as 5052, 6053 and 5056, are least severely attacked
in chloride media when galvanically coupled (). Hydrogen evolution
and strong alkalinity generated at the cathode can damage or destroy
organic coatings applied to fasteners or other accessories coupled to
magnesium. Alkali-resistant resins are necessary, but under severe
conditions, such as salt spray or salt immersion, which do not
simulate adequately a real application, the coatings may be simply
blown off by hydrogen, starting at small voids or pores. Some new
processing methods such as new rheocasting processes, rapid
solidification processes, ion implantation and vapor deposition
enhance corrosion resistance by producing a more homogeneous
microstructure and/or by increasing the solubility limits of alloying
additions (Shaw and Wolfe, 2005). This can be lead to more
corrosion-resistant passive states.
There is considerable interest in the use of magnesium alloys in
metal–matrix composites (MMCs). However, this is a strenuous
application for magnesium, considering the extreme galvanic nobility
of many composite materials, such as graphite. In the case of AZ91
combined with alumina fibres, the corrosion rate of the MMC is
seven times higher than that of the bulk alloy, showing the
paramount importance of galvanic effects (Shaw and Wolfe, 2005).
Hihara and Kondepudi (1993, 1994) investigated the
galvanic corrosion behavior of Mg MMCs of the two matrices: pure
Mg and ZE41A-Mg alloy in contact with SiC monofilament (MF) or
pure SiC particles. The results showed evidence of higher
galvanic corrosion rates of the matrices in both cases; however,
ZE41A–Mg matrix showed a better corrosion resistance than pure
Mg. Hall (1987) observed the evidence of galvanic corrosion for
carbon fiber/magnesium MMCs in a normal laboratory atmosphere
of about 60% relative humidity at 20 °C. The determined rate of
penetration was about 100 μm per year. Bakkar and Neubert (2009)
showed that the galvanic coupling with C-fibers leads to severe
corrosion of Mg matrix composites and invalidates the virtual effect
of alloying elements on corrosion resistance.
Read full chapter
is a list of metals in order of their activity, the most active being at the
top of the list and the least active at the bottom. The further apart two
metals are on this list, the greater will be the reactivity between them
and, therefore, the faster the anodic end will corrode.
Methods for the modification of the waterside environment to control
the rate of active galvanic corrosion include the following:
1. Eliminating the contact of dissimilar metals in an HVAC system
by using insulating couplings or joints such as a dielectric
insulator coupling, which interferes with the electron flow from
one metal to the other.
2. Eliminating one or more of the essential elements required for
galvanic corrosion to occur. This might require, for example,
modifying the HVAC system design by changing one of the
metallic materials of construction, such as zinc or copper.
3. The use of protective coatings and chemical corrosion inhibitors,
which all provide a physical or chemicophysical barrier between
the corroding metal and its environment.
Read full chapter
Corrosion
Michael J Schofield BSc, MSc, PhD, MIM, CEng, in Plant Engineer's
Reference Book (Second Edition), 2002
33.1.2.3 Galvanic corrosion
Galvanic corrosion is the enhanced corrosion of one metal by contact
with a more noble metal (or a conductive non-metal such as
graphite). The two metals require only to be in electrical contact with
each other and exposed to the same electrolyte environment. By
virtue of the potential difference that exists between the two metals,
the potential of the less noble (more reactive metal) is raised. This
stimulates corrosion of the more reactive metal, simultaneously
reducing the corrosion rate of the less reactive metal. This principle is
exploited in the cathodic protection (Section 33.7.2) of steel structures
by the sacrificial loss of aluminium or zinc anodes.
The metal that corrodes in any couple is that which has the most
negative corrosion potential in the galvanic series in that
environment. As a guidance, Table 33.1 is of general but not universal
applicability. Thus in the case of copper and aluminium the
aluminium corrodes unless corrosion inhibitors are employed.
Copper and aluminium are therefore not generally used in close
contact with each other, but copper ions in solution from the
corrosion of copper pipework can plate out onto aluminium items
(including saucepans) downstream in the system. Rapid corrosion of
the aluminium occurs in the region of the copper deposits. The
conductivity of the environment and the potential difference between
the metals involved determine whether the corrosion is localized to a
small region at the interface between the metals, or spread across a
larger region. The exposed areas of the two metals together with the
length of the conductance path in the electrolyte determine the
intensity of the attack. Other conditions, such as the flow regime and
the polarization behaviour of the two metals, influence
galvanic corrosion.
Potential reversal is a complicating factor in galvanic corrosion. Zinc
is usually anodic to steel and hence it is used to protect steel
sacrificially. Galvanized steel is steel coated with zinc. The zinc
protects any steel that is exposed (such as cut ends of sheet) and
scratches through the zinc layer. At temperatures above 80° C, in low-
conductivity water (e.g. condensation) the metals undergo a reversal
of polarity. The steel corrodes in preference to the zinc, and this

Magnesium (Mg) corrosion protection
techniques in the automotive industry
G.S. Cole, in Corrosion Prevention of Magnesium Alloys, 2013
18.3.1 Corrosion and Mg alloy contamination
Galvanic corrosion is hard to predict since some metals polarize in
the electrolyte (form a protective oxide), so where a galvanic couple is
expected, none occurs. But if there are Ni, Fe and/or Cu impurities in
the cathodic material, they can dominate the polarization so that
galvanic corrosion may still occur, even at very low levels of impurity
due to solidification segregation, as discussed previously. AXJ530 Mg
alloy (5% Al, 3% Ca) was developed by researchers at General Motors
(GM) several years ago (Powell and Rezhets, 2001). Its excellent high
temperature creep resistance, castability and low cost made it an
attractive material for powertrain applications. The automotive
industry requires that the inventor of a new alloy cross-licenses at
least three suppliers who can produce the alloy; in case one supplier
runs into difficulties (financial and/or production issues such as a
strike or fire), there will always be an approved supplier as back-up.
When the GM engineers surveyed potential Mg alloy suppliers, they
observed inconsistent corrosion data. In particular, specimens cast by
one vendor showed 20 times the environmental corrosion of
specimens cast elsewhere, with no correlation among the usual
corrosion causes, associated with Fe, Ni or Cu contamination.
Without a clear understanding of the corrosion variability, GM’s
confidence in using AXJ530 was undermined, and this prevented its
initial application in automotive components.
It is well-known that the solubility of Fe in Mg is related to Mn
content (). Recently , using phase diagram calculations, determined
that the presence of submicron Fe-rich phases, precipitated during
solidification, could serve as active catalysts for electrochemical attack.
GM researchers reassessed the initial problem and recalculated the
phase diagram of alloy AXJ530 with different Mn content. They
determined the Fe-rich phase-precipitation region in the presence of
different Mn levels, and measured the corrosion performance of
HPDC samples cast at different temperatures. A small Mn chemical
composition-difference and/or casting temperature variation changed
the precipitation behavior of the Fe-rich phases and significantly
changed corrosion behavior of the alloy. Increasing the Mn content
and/or lowering the casting temperature (which allowed Fe-rich
phases to precipitate and settle out of solution to the bottom of the
melting pot), improved the corrosion resistance of the AXJ530
magnesium alloy. A new series of cast AXJ530 alloy samples based on
these suggestions showed consistently low corrosion rates, and will
be the basis for a re-evaluation of the alloy regarding its readiness for
production.
Read full chapter
causes rapid loss of the zinc, which can fall off in sheets as corrosion
proceeds along the steel surface undermining the zinc. Tin is usually
more corrosion resistant than steel, hence its use in tinplate (tin-
plated steel). In some organic acids, including some of those
encountered in fruit juices, the relative potentials of tin and steel are
reversed and the tin corrodes, contaminating foodstuffs with tin
corrosion products.
The corrosion potentials of metals and alloys are temperature
dependent. The potential of a steel distillation column, heat
exchanger or other item of plant varies in the temperature zones in
which it is operating. Under some circumstances this creates
galvanic corrosion cells between different areas of one item fabricated
from one material, leading to localized galvanic corrosion problems.
To avoid galvanic problems, different materials of construction may
have to be electrically isolated or at least the electrical resistance
between them increased to a level sufficient to reduce the corrosion
current to an acceptable value. In some instances it is more practical
to paint or otherwise coat the more cathodic of the two parts of the
couple. The anodic material should not be coated, since even more
rapid penetration would occur at any breaks in the coating. Guidance
on the galvanic hazards posed by the contact of different materials of
construction is given in the British Standard publication PD 6484.
Read full chapter
Metal Matrix Composites
P.K. ROHATGI, in Comprehensive Composite Materials, 2000
3.18.2 Galvanic Corrosion
Galvanic corrosion is a major concern in metal matrix composites.
Galvanic corrosion takes place as a result of one metal being in
contact with another in a conducting, corrosive environment. The
corrosion is stimulated by the potential difference that exists between
the two materials, the more noble material acting as a cathode and
the more active, which corrodes, acting as the anode. The anodic
reaction is some form of metal dissolution and the cathodic reaction
is either oxygen reduction or hydrogen evolution. Common
reinforcements such as SiC, graphite, and alumina are more noble
than the metallic matrix, and this can result in accelerated corrosion
of the matrix. In addition, during processing, the reinforcements
could react with the matrix and form new phases that are more noble
than the matrix. This can also lead to galvanic corrosion between the
matrix and the reinforcements, leading to a higher corrosion rate of
the matrix.
When two materials are connected together as in a galvanic couple,
mixed potential theory is used to understand their corrosion behavior.
Likewise, the corrosion behavior of metal matrix composites can
sometimes be predicted by using the mixed potential theory shown in
Figure 1 (Hihara and Latanision, 1994). This figure shows that the
corrosion current (Icorr) of the matrix and galvanic current density
(Igalv) between the matrix and reinforcement is influenced by the
anodic polarization curves of the matrix and cathodic polarization
curves of the reinforcements, as well as the environmental conditions.
Therefore, the combination of the individual polarization curves of the
matrix and the reinforcements may help in predicting the corrosion
behavior of metal matrix composites.
In Figure 1(a) and (b), the curves of anodic polarization show that the
metal dissolution rate increases by increasing the potential. The
formation of a passive film that protects the melt leads to a decrease
in the melt dissolution rate, as shown in Figure 1(c). However,
destruction of the passive film results in an increase in the corrosion
rate. In chlorides and other halide environments, the passive film is
 damaged and then the pit forms, leading to an increase in the
corrosion rate (Figure 1(d)).
In Figure 1, as the metal is more active than the reinforcements, Icorr
increases up to Igalv in deaerated conditions, and to a higher value of
Igalv in aerated conditions. If the activity of the proton is increased,
Igalv increases. This effect raises the corrosion rate of the matrix.
Figure 1(b) shows the case where Igalv is the same for deaerated and
aerated conditions. In Figure 1(c), the matrix alloy shows the
formation of passive film. The anodic polarization curve shows that
Icorr increases up to Igalv in deaerated conditions; however, under
aerated conditions, unlike the diagrams shown in Figure 1(a) and (b),
Icorr is lower up to Igalv due to anodic protection taking place when an
active and passive metal is coupled to a noble reinforcement. Figure
1(d) shows a case when Icorr is identical to Igalv due to passivation of
the metal in a halide- free environment. For a halide-containing
environment, dissolution of passive metal occurs and the metal will
be pitted.
In fact, the curves shown in Figure 1 are for the simple cases. The
positions of these curves depend on many factors, including reaction
kinetics (metal dissolution, oxygen reduction, and hydrogen
evolution), alloy composition (major constituent, minor constituent,
and impurity), mass transport (diffusion and convection), solution
environment (temperature and flow rate), solution propriety, and total
geometry (area ratio between the matrix and reinforcement, surface
conditions), etc. To obtain quantitative predictions of galvanic
currents requires all these factors to be considered. The mixed
potential theory is sometimes useful to estimate the corrosion
behavior of metal matrix composites. However, the behavior predicted
using mixed potential theory does not agree with the actual corrosion
behavior due to the facts mentioned above. In addition, the actual
corrosion behavior can differ from the behavior predicted by the
mixed potential theory: (i) due to the formation of a new phase as a
result of reaction between the reinforcements and the matrix, (ii) the
segregation of alloying elements around the reinforcements, (iii)
residual contaminants, and (iv) change in the nature of the matrix
near the interfaces; the coatings also influence the corrosion behavior
and their effect does not show up in certain eletrolytes. The mixed
potential theory, however, does help to some extent in identifying the
desirable reinforcements that can be used to develop MMCs, as a first
educated guess.

Read full chapter

View full topic index

About ScienceDirect Remote access Shopping cart Contact and support Terms and conditions Privacy policy

We use cookies to help provide and enhance our service and tailor content and ads. By continuing you agree to the use of cookies.
Copyright © 2018 Elsevier B.V. or its licensors or contributors. ScienceDirect ® is a registered trademark of Elsevier B.V.