We know that aluminium will be corroded in contact with copper. So how copper clad aluminium conductors can remain safe?
Dear Farhad Yazdi
if there is no conductive electrolyte solution contacting with both metal (when the cladding copper has no pores) no galvanic corrosion occurs in such case, but when the cladding copper has some pores galvanic corrosion may occur, to avoid this kind of corrosion, you can cover the copper with nickel as in the special batteries.
Dear Dr. Farhad Yazdi,
there is only a “potential damage” due to galvanic corrosion of copper clad aluminum if the wires are exposed to any electrolyte (battery acid, salt water, humid sea coast, etc). The potential for corrosion is not due to the current carried by the wires, but due to the dissimilar metals. The corrosion will occur at any defect in the copper plating where aluminum is exposed. The corrosion potential in this case is extremely high due to the very large cathode area of copper and the small anode area of exposed aluminum.
The damage will be localized to the exposed area, so may not be a problem functionally for some time. But the white aluminum corrosion product may be quite unaesthetic.
Best regards, Pierluigi Traverso
Congratulations to Juan Genesca for the provided literature. a wonderfully presented scientific publication. I agree with the opinion of Pierluigi Traverso.
Corrosion with a well-made galvanic coating of Cu over Al can last a long time. In the event of cracking on a copper sheath, the corrosion of the conductor will start without corrosion due to the difference in the conductivity of Cu and Al. In addition, thermal conductivity is different. In the case of mild heating, different temperature extensions are caused which cause micro cracks in the wiring process, even though it is in a protected environment. The presence of moisture or electrolyte only contributes to the acceleration of the corrosion process.
Regards Emil Yankov
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