Copyright 2010 Midas Technologies Ltd.

All rights reserved

Technical Bulletin
Telephone | +44 (0)1733 342600
Email | technicalsales@midastech.co.uk
Website | www.midastech.co.uk
Galvanic Corrision Guide Let the Buyer have Faith
What is Galvanic Corrosion?
Galvanic corrosion is the corrosion that results when two dissimilar
metals with different potentials are placed in electrical contact in
an electrolyte or other conductable uid or media. A difference in
electrical potential exists between the different metals and serves
as the driving force for electrical current to ow through the uid 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, active
metal becomes the anodic corrosion site. The stronger, more noble metal is cathodic and
protected. Galvanic corrosion potential is a measure of how dissimilar metals will corrode
when placed against each other in an assembly. Metals close to one another on the chart
generally do not have a strong effect on one another, but the farther apart any two metals
are separated, the stronger the corroding effect on the one higher in the table.
The table (left) that follows lists the potential differences for various metals in water with
the table right indicating electrode potential. The order of the series can change for
different electrolytes (for example, different pH, ions in solution, stagnant media,
aerated or non aerated).

Often when design requires that dissimilar metals come in contact, the galvanic compatibility is managed by nishes,
isolation washers and plating. The nishing 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 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.
If a noble metal like stainless steel has a large surface area in contact with the electrolyte while the sacricial metal
(such as galvanised steel) has a very small surface area in contact with the electrolyte, then the stainless steel will
generate a large corrosion current which will be concentrated on a small area of sacricial metal. The galvanised
steel will corrode quickly ? rst the zinc then the underlying steel ? and so galvanised fasteners in stainless steel
are not acceptable.
However, a stainless screw in galvanised steel is frequently used although a mound of zinc corrosion product will
accumulate around the fastener. This is because the ratio of wetted noble fastener in an active metal might change
from a 1:50 ratio to 1:1 during drying after a rainstorm. If contaminants are signicant this means that avoiding
dissimilar metal pairs may be a preferred option to prevent galvanic attack.
As a rule of thumb, if the wetted area of the corroding metal is 10 times the wetted area of the noble metal,
then galvanic effects are not serious although the larger the ratio the less the effect.
Copyright 2010 Midas Technologies Ltd. All rights reserved
Galvanic Corrision Guide Let the Buyer have Faith
Continued
Page 2
Galvanic Corrosion Chart
Magnesium Alloys
Zinc
Beryllium
Aluminum 1100, 3003, 3004, 5052, 6053
Cadmium
Aluminum 2017, 2024, 2117
Mild Steel 1018, Wrought Iron
HSLA Steel, Cast Iron
Chrome Iron (active)
430 Stainless (active)
302, 303, 321, 347, 410, 416 Stainless Steel (active)
Ni-Resist
316, 317 Stainless (active)
Carpenter 20Cb-3 Stainless (active)
Aluminum Bronze (CA687)
Hastelloy C(active) Inconel 625(active) Titanium (active)
Lead/Tin Solder
Lead
Tin
Inconel 600 (active)
Nickel (active)
60% Ni 15% Cr (active)
80% Ni 20% Cr (active)
Hastelloy B (active)
Naval Brass (CA464), Yellow Brass (CA268)
Red Brass (CA230), Admiralty Brass (CA443)
Copper (CA102)
Manganese Bronze(CA675), Tin Bronze(CA903, 905)
410, 416 Stainless(passive) Phosphor Bronze(CA521, 524)
Silicon Bronze (CA651, 655)
Nickel Silver (CA 732, 735, 745, 752, 754, 757, 765, 770, 794
Cupro Nickel 90-10
Cupro Nickel 80-20
430 Stainless (passive)
Cupro Nickel 70-30
Nickel Aluminum Bronze (CA630, 632)
Monel 400, K500
Silver Solder
Nickel (passive)
60% Ni 15% Cr (passive)
Iconel 600 (passive)
80% Ni 20% Cr (passive)
Chrome Iron (passive)
302, 303, 304, 321, 347 Stainless (passive)
316, 317 Stainless (passive)
Carpenter 20Cb-3 Stainless (passive), Incoloy 825 (passive)
Silver
Titanium (passive), Hastelloy C & C276 (passive)
Graphite
Zirconium
Gold
Platinum
Magnesium Anodic
(least noble)
Corroded
Direction
of attack
Cathodic
(most noble)
Protected
Electrode Potential at 77 F (25 C)
Anodic end (this is where the corrosion occurs)
Element Standard
Electrode
Potential
(Volts)
Lithium -3.045
Potassium -2.920
Sodium -2.712
Magnesium -2.340
Beryllium -1.700
Aluminum -1.670
Manganese -1.050
Zinc -0.762
Chromium -0.744
Iron; Mild Steel -0.440
Cadmium -0.402
Yellow Brass -0.350
50-50 Tin-Lead Solder -0.325
Cobalt -0.277
Nickel -0.250
Tin -0.136
Lead -0.126
Hydrogen reference electrode 0.000
Titanium +0.055
Copper +0.340
Mercury +0.789
Silver +0.799
Carbon +0.810
Platinum +1.200
Gold +1.420
Graphite +2.250
Cathodic end, passive (no corrosion here)
Copyright 2010 Midas Technologies Ltd. All rights reserved
Galvanic Corrision Guide Let the Buyer have Faith
Continued
Page 3
Stainless steel has an effective passive lm so the available corrosion current is quite low. If the behaviour of a
copper/steel and a stainless steel/steel couple is compared, the copper/steel coupling is a more signicant galvanic
problem despite the similar potential separation of 0.35 volts.
Examples of acceptable galvanic pairs include:
Galvanised steel pipe hangers are used to hang stainless steel piping externally around chemical plants. The surface
area ratio is bad with large area of stainless steel to small area of active zinc/steel but the rainwater is usually of quite
low conductivity and 20 year service life is normal.
In the water industries, galling between stainless steel threads and nuts has been avoided by using aluminium bronze
nuts on stainless steel studs or bolts. Although aluminium bronze is more active than stainless steel, the conductivity
of the water, and hence the corrosion rate, is generally quite low. The nuts will require replacement but only at times
of major overhaul.
One unacceptable case was a gasket with a carbon black loading so high it was conductive and caused severe
galvanic attack of a 316 stainless lug. Graphite gaskets have caused similar problems.
The most severe conditions are in swimming pool / leisure club environments and serious incidents have occurred to
the extent of roofs collapsing, applications for these should be properly documented and authorised.
Useless information or not?
A lasagna cell or lasagna battery is accidentally produced
when salty food such as lasagna is stored in a steel baking pan
and is covered with aluminum foil. After a few hours the foil
develops small holes where it touches the lasagna, and the
food surface becomes covered with small spots composed
of corroded aluminum.
This metal corrosion occurs because whenever two metal sheets composed of differing
metals are placed into contact with an electrolyte, the two metals act as electrodes, and
an electrolytic cell or battery is formed. In this case, the two terminals of the battery are
connected together. Because the aluminum foil touches the steel, this battery is shorted out,
a signicant electric current appears, and rapid chemical reactions take place on the surfaces
of the metal in contact with the electrolyte. In a steel/salt/aluminum battery, the aluminum is
higher on the electrochemical series, so the solid aluminum turns into dissolved ions and the
metal experiences galvanic corrosion. If tomato ketchup was added to the top of the lasagna
this would accelerate the process as the ketchup is highly acidic this would turn the aluminium
foil into a grey mush on top of the lasagna.
Copyright 2010 Midas Technologies Ltd. All rights reserved
Our only Limitation is your Imagination
Midas Technologies (GB) Ltd, Midas House, Roundhouse Close, Eastern Industry, Peterborough, PE1 5TA
Telephone | +44 (0)1733 342600 Facsimile | +44 (0)1733 346672 Email | sales@midastech.co.uk
Midas Technologies have provided this information in good faith based on their experience, sample test and research and development, together with freely
available from other resources. We will not be responsible for any actions taken in respect of the information herein unless we are under contracts for the
works. A compreensive Quality Assurance system is required from design and procurement of materials to installation.
We recommend the use of ISO 9000:2000 registered rms.
The technical recommendations contained in this publication are necessarily of a general nature and should not be relied on for specic applications without
rst securing competent advice. Whilst Midas Technologies has taken all resonable steps to ensure the information contained herein is accurate and current
it does not warrant the accuracy or completeness of the information and does not accept liability for errors or omissions.
Corrision Class 0
Indoors with relative Humidity under 60%.
Very Low Corrosion Risk
Corrision Class 1
Indoors in non-heated, well ventilated room.
Low Corrosion Risk.
Corrision Class 2
Indoors with uctuating temperature and humidity.
Outdoor in inland climates, far from the sea and industry.
Medium Corrosion Risk.
Corrision Class 3
In densely populated areas or near industrial areas.
In the vicinity of open water and near the coast.
High Corrosion Risk
Corrision Class 4
Constant, high humidity. Near industry manufacturing or utilizing chemicals.
Very High Corrosion Risk.
With careful consideration during the design process galvanic
corrosion can be avoided, be specic in pre treatments
and nal coatings such as degreasing, shot or glass bead
blasting, chromate pre treatment, galvanising, zinc plating,
polyester powder coating etc.