Galvanic corrosion is a major problem impacting aerospace platform design, retrofit, and maintenance. MIL-STD-889 provides guidance on dissimilar material selection based on the corrosion potential of materials in flowing seawater. This standard provides a general guide for materials selection, but contains a limited material database and does not account for corrosion rates in addition to corrosion potential. To better inform materials selection during design and/or retrofit, an interactive galvanic corrosion predictor tool (GCPT) has been developed that quantitatively predicts corrosion rates. The GCPT is a computational engine that predicts pitting corrosion and galvanic corrosion rates between dissimilar materials. Galvanic interactions between dissimilar materials are modeled using a curve-crossing algorithm based on the Theory of Mixed Potentials. Furthermore, the GCPT and its material database have been coupled with computer-assisted design (CAD) software to enable galvanic simulations of coating systems, sub-assemblies, and large-scale platform models. This enables designers and material and process (MP) engineers to rapidly assess galvanic corrosion risks prior to material qualification and implementation, rather than relying solely on engineering judgment or service history.
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