GALVANIC CORROSION

Galvanic corrosion is an electrochemical process in which one metal corrodes preferentially to another when both metals are in electrical contact and immersed in an electrolyte. The same galvanic reaction is exploited in primary batteries to generate a voltage.
GALVANIC CELL

is a cell in which the chemical change is the source of

energy. : the corrosion which is caused due to the formation of the galvanic cell is called galvanic corrosion.
GALVANIC CORROSION

When a galvanic couple forms, one of the metals in the couple becomes the anode and corrodes faster than it would all by itself, while the other becomes the cathode and corrodes slower than it would alone. For galvanic corrosion to occur, three conditions must be present: 1. Electrochemically dissimilar metals must be present 2. These metals must be in electrical contact, and 3. The metals must be exposed to an electrolyte The relative nobility of a material can be predicted by measuring its corrosion potential. Metals can be arranged in a galvanic series representing the potential they develop in a given electrolyte against a standard reference electrode. The relative position of two metals on such a series gives a good indication of which metal is more likely to corrode more quickly. However, other factors such as water aeration and flow rate can influence the process markedly

Galvanic Series*

Magnesium Zinc Aluminum (most types) Iron, plain carbon and low alloy steels Lead, high lead alloys Tin plate, tin/lead solder Chromium plated materials, chromium alloys, chromium typesteels Brass Copper Nickel Stainless steels Silver Gold

OVERVIEW :
Dissimilar metals and alloys have different electrode potential and when two or more come into contact in an electrolyte a galvanic couple is set up, one metal acting as anode and the other as cathode. The potential difference between the dissimilar metals is the driving force for the accelerated attack on the anode member of the galvanic couple. The anode metal dissolves into the electrolyte, and deposition is formed on the cathodic metal. The 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 an electrolyte and a electronic conducting path between the metals is essential for galvanic corrosion to occur. In some cases, this reaction is intentionally encouraged. For example, low-cost household batteries typically contain carbon- zinc cells. As part

of a closed circuit (the electron pathway), the zinc within the cell will corrode preferentially (the ion pathway). Another example is the cathodic protection of buried or submerged structures. In this example, sacrificial anode work as part of a galvanic couple, promoting corrosion of the anode, rather than the protected subject metal.

This new manifold for water meters has replaced the old one after 4 years of use, having been connected directly to a copper pipe in the building (0.85 V of potential difference, see the point of corrosion in the bottom left). With a PVC battery support, lifetime is unlimited.

MECHANISM OF GALVANIC CORROSION: For the formation of a galvanic cell the following components are required: A anode A cathode An electrolyte A metallic path for electric current In case of copper and steel, copper act as a cathode and iron as anode as per emf series. As a matter of principle, in a galvanic cell, the more noble metal always becomes the cathode and vice versa. Moisture act as an electrolyte and the metal surface provides the metallic path for the electron current to flow.

The positive ions (Fe++) flow from the anode (iron) to cathode (copper) through the electrolyte water. Iron, therefore corrodes. The Hydrogen ions(H+) are discharged at copper cathode and ultimately Hydrogen is released. The (Fe++) ions travels towards the cathode and OH- towards anode. They combine to form insoluble iron hydroxide Fe(OH)2. Conventional current flows from cathode to anode through the external metallic path. In the electrolyte the electric current flows from anode to cathode by positive cations. From the cathode to anode it is carried out by anions. The electrons are being released by the anodic dissolution of iron participated in the reduction process such as 2H+ + 2e H2 OR Cu2+ +2e Cu
EXAMPLE:

The above picture shows a galvanized steel tank with a copper inlet pipe and an Al tank with an Al water inlet pipe. The steel tank would corrode as shown. Copper ions in the tank which are leached from the copper pipe would deposit on the wall of the tank and form a galvanic cell , hence the galvanized steel tank will corrode.

Hence the more active metals will corrode whereas the less active or noble metal does not corrode. FACTORS AFFECTING GALVANIC CORROSION:

: Position of metals in the galvanic series. : The nature of the environment (marine environments) : Area , distance and geometric effects. ( Rate of corrosion increases with the ratio of cathodic to anodic areas).

HISTORIC EXAMPLES OF CORROSION:

A common example of galvanic corrosion is the rusting of corrugated iron sheet, which becomes widespread when the protective zinc coating is broken and the underlying steel is attacked. The zinc is attacked preferentially because it is less noble, but when consumed, rusting will occur in earnest. Statue of Liberty

A rather more spectacular example occurred in the Statue of liberty when regular maintenance in the 1980s showed that galvanic corrosion had taken place between the outer copper skin and the wrought iron support structure. Regular maintenance showed that the Statue of Liberty suffered from galvanic corrosion Although the problem had been anticipated when the structure was built by Gustave Eiffel to Frederic Bartholdi's design in the 1880s, the

insulation of shellac between the two metals failed over a period of time and resulted in rusting of the iron supports Lasagna cell A "Lasanga cell" is accidentally produced when salty food such as lasagna is stored in a steel baking pan and is covered with aluminium 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 aluminium. In this example, the salty food (e.g. lasagna) is the electrolyte, the aluminium foil the anode and the steel pan the cathode. If the aluminium foil only touches the electrolyte in small areas, the galvanic corrosion is concentrated and corrosion can occur fairly rapidly.

APPLICATION AND PRINCIPLES OF GALVANIC CORROSION: : Non metallic conductors : Metallic coatings : Cathodic protection

EXAMPLES OF FAILURES OF GALVANIC CORROSION : : Galvanic corrosion of Al shielding in buried telephones cables. : Galvanic corrosion of steel pipe with brass fittings. : Galvanic corrosion of the body of the ship in contact with the brass or Bronze propellers.

: Galvanic corrosion of steel coated with copper due to the defects in copper coatings. : Al conduit buried in steel reinforced concrete. : Galvanic corrosion inside horizontal stabilizers in aircrafts.

METHODS OF PREVENTION OF GALVANIC CORROSION : 1. Select the metals, closed together, as far as possible, in Galvanic series. 2. Do not have area of more active metal smaller than the noble metal. 3. If dissimilar metals are to be used, insulate them. 4. Use inhibitors in aqueous system when ever applicable and eliminate cathodic depolarizers. 5. Apply coating with judgement. Do not coat the anodic member of the couple as it would reduce the anodic area. 6. Avoid joining the materials by threaded joints. 7. Sacrificial material , such as Zinc or magnesium, may be introduced into this assembly. For instance zinc anodes are used in cast iron water boxes of copper alloy water- cooled heat exchangers. 8. In designing the components, use replaceable parts so that only the corroded parts could be replaced instead of the whole assembly.