A COMPARATIVE STUDY OF ANTI-CORROSION TECHNIQUES AT COPPER–ALUMINIUM JOINTS

Abstract

The integration of copper–aluminium (Cu–Al) joints in automotive, electrical, and HVAC systems has increased due to the demand for lightweight designs combined with efficient electrical and thermal performance. However, the inherent electrochemical mismatch between copper and aluminium results in galvanic interactions that accelerate interfacial corrosion, ultimately limiting joint reliability. This work presents a comparative assessment of six corrosion mitigation approaches, namely zinc-based interlayers, electroless nickel coatings, aluminium anodizing, chromate and trivalent conversion coatings, dielectric isolation techniques, and polymeric sealing systems. Each method is evaluated with respect to corrosion protection capability, service durability, production compatibility, cost efficiency, and environmental considerations. Based on the comparative analysis, practical selection criteria are formulated to assist engineers in selecting appropriate anti-corrosion solutions for varying operational conditions.