Galvanic Corrosion in Water and Wastewater Structures: Coupling Stainless Steel and Carbon Steel Metals Leads to Accelerated Corrosion

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Galvanic corrosion is one of the eight forms of corrosion classified in corrosion engineering. A galvanic cell is formed when two dissimilar metals are connected electrically while both are immersed in a solution electrolyte. Galvanic coupling of stainless steel and carbon steel metals in water and wastewater structures appears to be a problematic trend that the authors have observed firsthand.

Product Number: 51323-19447-SG

Author: Vaughn O’Dea, Dean Wenger, Brian Cheshire

Publication Date: 2023

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Stainless steel is often selected for use in the municipal waterworks industry because of its inherent
corrosion resistance properties. Designers, Original Equipment Manufacturers, and Constructors
oftentimes overlook the associated problems with coupling stainless steel with carbon steel metals when
designing, fabricating, or erecting water and wastewater structures. These connections between metals
may be created by welding, bolting, or other electrical contact. As a result, accelerated corrosion of the
anodic carbon steel metal is often initiated when these materials are electrically connected and placed
into immersion service environments.

This paper will review the galvanic corrosion theory, provide examples where bare stainless steel and
coated carbon steel metals were coupled in water and wastewater structures, and provide
recommendations on how to minimize the effects of galvanic coupling stainless steel with carbon steel
metals.