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Galvanic Corrosion of Tinned Copper Coupled with Aluminium Alloy in Electric Vehicle

Picture for Galvanic Corrosion of Tinned Copper Coupled with Aluminium Alloy in Electric Vehicle
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Recently, as environmental regulations have become more severe, the demand for electric vehicles (EV) has increased In the EV system, previously mechanically controlled parts become electrically operated. Accordingly, stable electrical connection between the parts using a wiring harness is becoming more important for reliable operation of the EV. Tinned Cu, whose resistance to both corrosion and wear is excellent, is widely used for wire and terminal for wiring harnesses.

Product Number: 51323-19239-SG
Author: Jeong-Min Lim, Seung-Ho Ahn, Byung-Su Kim, Jung-Gu Kim
Publication Date: 2023
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$20.00

In this study, the galvanic corrosion behavior of the tinned Cu terminal coupled with Al–Mg–Si alloy was analyzed. When the Al, Sn and Cu were exposed to the electrolyte, tri–metallic galvanic corrosion occurred between them. The polarization curves show that the corrosion potential increases in the order: Al < Sn < Cu. Therefore, when the tinned Cu is coupled with Al–Mg–Si alloy, Al alloy with the lowest corrosion potential becomes the anode, while Cu with the highest corrosion potential becomes the cathode. Sn, which has an intermediate potential, becomes either anode or cathode. Since all three metals have steeper cathodic Tafel slopes than an anodic Tafel slopes, the galvanic corrosion rate is determined by the area of cathode. Therefore, the area ratio of Sn and Cu to Al alloy is the main factor affecting the total corrosion rate of the Al–tinned Cu couple. The ZRA results and the Tafel relationship show that the total galvanic corrosion rate increases as the area ratio of Sn plating decreases. Consequently, to prevent failure by corrosion of the connection of the Al body and the tinned Cu terminal, their joining should be performed to minimize damage to the Sn plating.

In this study, the galvanic corrosion behavior of the tinned Cu terminal coupled with Al–Mg–Si alloy was analyzed. When the Al, Sn and Cu were exposed to the electrolyte, tri–metallic galvanic corrosion occurred between them. The polarization curves show that the corrosion potential increases in the order: Al < Sn < Cu. Therefore, when the tinned Cu is coupled with Al–Mg–Si alloy, Al alloy with the lowest corrosion potential becomes the anode, while Cu with the highest corrosion potential becomes the cathode. Sn, which has an intermediate potential, becomes either anode or cathode. Since all three metals have steeper cathodic Tafel slopes than an anodic Tafel slopes, the galvanic corrosion rate is determined by the area of cathode. Therefore, the area ratio of Sn and Cu to Al alloy is the main factor affecting the total corrosion rate of the Al–tinned Cu couple. The ZRA results and the Tafel relationship show that the total galvanic corrosion rate increases as the area ratio of Sn plating decreases. Consequently, to prevent failure by corrosion of the connection of the Al body and the tinned Cu terminal, their joining should be performed to minimize damage to the Sn plating.

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Failures of Brass Components in Water and Steam Systems

Product Number: 51317--9123-SG
ISBN: 9123 2017 CP
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