To prevent galvanic corrosion, engineers must break the electrochemical link between dissimilar metals that are exposed to an electrolyte, such as moisture, saltwater, or condensation. Common strategies include:
- Choose similar metals: Select materials that are close together in the galvanic series to minimize potential differences.
- Add electrical insulation: Use non-conductive washers, bushings, or gaskets to block direct contact.
- Apply protective coatings: Barrier coatings, such as Thin Dense Chrome (TDC), isolate metal surfaces from electrolytes.
- Control the environment: Improve drainage, reduce humidity, seal joints, or use corrosion inhibitors.
- Use sacrificial anodes: In marine or buried systems, a more reactive metal like zinc can corrode in place of the protected part.
For more on how galvanic corrosion starts and how to stop it, see our blog post Understanding Galvanic Corrosion: Causes, Prevention, and Solutions.