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Galvanic and
Stray Current Corrosion
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Overview
• Galvanic Corrosion
Understanding Galvanic Corrosion
Controlling Galvanic Corrosion
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Galvanic Corrosion
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Causes
• Requires
Two different metals (electrodes)
Immersed in current-carrying solution (electrolyte)
Interconnected by a current-carrying conductor
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Results
of Galvanic Corrosion
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Galvanic Scale of Metals
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Types of Metal
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Area of Metal
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Self-Destroying Metals
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Use of Sacrificial Anodes
• Made from active metals
Magnesium, zinc or aluminum
• Corrosive action occurs on the expendable
metal anode
• Bolted to the metal they are to protect
• Never painted
• Replaced when half-corroded or annually
Trim Tab
6 Zincs
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Indirect Cathodic Protection
• Used when direct contact not possible
Zinc bolted to outside of hull
Inside boat connect with insulated AWG#8 to
• Rudder Post
• Shaft (requires shaft brush)
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Resistance of Electrical Path
• Fresh water is less conductive than salt water
Less galvanic current
Use magnesium sacrificial anodes
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Between Boats
• Two different metals
Aluminum vs steel (or other metal)
Immersed in current-carrying solution
• Sea water
Interconnected by current-carrying conductor
• AC ground (green) wire
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Galvanic Isolator
or Isolation Transformer
• Stops DC current in AC ground wire
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Stray Current Corrosion
• Requires
External source of electricity
From wetted metal surface (electrodes)
To return circuit of lower potential
(electrolyte)
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Stray vs Galvanic Current
• Stray current corrosion is more destructive
Hundreds of times stronger
Galvanic potential difference 0.25 to 1.5 volts
Stray current from 12 volt battery
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Results
of Stray Current Corrosion
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Additional Notes
• Stronger than Galvanic current
100 times more destructive
• Metals can be similar or dissimilar
Current flow from positive through electrolyte
Positive DC terminal will corrode
Both AC terminals will corrode
• Electrolyte is any moist surface
Bilge water
Wet wood
Wet or moist surface
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Stray Current Corrosion
Preventing Stray Current
• Wiring
• Bonding
• Battery charger
• Galvanic isolators
• Isolation transformers
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Wiring
• Defective wiring is the most common cause
Deteriorated insulation on hot wire
Always use marine grade wires
• Run wires above water line
Moist or wetted surfaces conduct current
Moisture in loose connections will cause
corrosion
• Wires in bilge
Waterproof terminals and butt spices
Heat shrink tubing is 2nd choice
Liquid electrical tape is also an option
Electrical tape is inadequate
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Bonding
• Maintain adequate bonding system
All metallic bodies and surfaces at DC negative
Chapter 2 (Wiring) covered bonding
• Propeller shaft bonding
Recommend by some authorities
Will also reduce propeller “hash” (Chapter 7)
Requires a shaft brush
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AC Ground Isolation
• If your boat has the better ground…
and a nearby boat has stray current
• Your boat will be damaged, unless…
• Stop DC current in AC ground wire
– Galvanic Isolators & Isolation Transformers
but
• Stray current may flow through your
boat
• In one underwater fitting
• Through bonding system
• Out another underwater fitting
(remember corroded prop and shaft pictures)
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Corrosion Facts
• Not all corrosion is electrical
Seawater deteriorates all metals
Cavitation also erodes props
• Stray current corrosion can be
eliminated
• Galvanic corrosion can be reduced
and controlled
• DC current is 100 times worse than
AC current
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Testing for Stray Current
• Measuring Stray Current
• Corrosion Source and Mitigation
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Measuring Stray Current
• Normally AC ground and DC negative connected
• To measure current, insert ammeter in series
AC DC
Gnd Neg
To To
ABYC Req
Shore A Battery
Power Temporary Negative
Bus break wire Bus
Bar to insert Bar
Ammeter
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AC Stray Current Testing
• AC main circuit breaker “On”
All branch circuit breakers “Off”
• Set multimeter to read AC current
• Current should be less than 1 milliampere
• Then selectively turn on each AC circuit
• If AC current exceeds 1 mA
You have stray current in that circuit
• After testing
Reconnect AC ground & DC negative bus bars
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DC Stray Current Testing
• DC main circuit breaker “On”
All branch circuit breakers “Off”
• Set multimeter to read DC current
• Current should be less than 0.01 milliampere
• Then selectively turn on each DC circuit
• If DC current exceeds 0.01 mA
You have stray current in that circuit
• After testing
Reconnect AC ground and DC negative bus bars
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Testing with Mitigation
• Galvanic Isolators & Isolation Transformers
Stop DC current
• To check for stray current with isolator
Place ammeter between DC negative bus and
green shore power wire to isolator
• To check for stray current with transformer
Place ammeter between DC negative bus and
green shore power wire to transformer
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Internal DC Current Testing
• Turn off DC main and all branch breakers
• Insert ammeter in battery negative cable
• Hold down bilge pump float switch
So pump will not turn on
• Turn on DC main and bilge pump breaker
• Measure stray current, if any
Defective wiring or pump switch
• Test other wiring with DC devices turned off
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Summary 1
• Types of electronic corrosion
Galvanic caused by dissimilar metals
Stray current requires external current
• Galvanic current
Requires
• Different metals
• Immersed in current carrying solution
• Connect together by current carrying conductor
Brass will disintegrate in sea water
Zincs are used to protect other metal
components
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Summary 2
• Stray current
Requires an external source of current
Normally is caused by defective wiring
• Especially in / through bilge
– Make sure any connections are waterproof
DC is 100 times more destructive than AC
• Over 1 mA AC
• Over 0.01 mA DC
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