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In this video we discuss galvanic corrosion between carbon fiber and aluminum, the electrochemical mechanisms that cause this type of corrosion, and the methods we use in the DarkAero 1 to prevent it.

There are three conditions that must be met in order for galvanic corrosion to occur:
1. Two different materials of different electrode potential.
2. The materials must be in electrical contact.
3. An electrolyte bridge must be present.

In honeycomb sandwich panel structures that use incorporate an aluminum honeycomb core and carbon fiber skin, we add in a thin layer of fiberglass to electrically isolate the carbon fiber from the aluminum.

We also use paint as a non conductive coating to electrically isolate carbon fiber from metals.

The Click Bond fasteners we use are electrically isolated from the carbon fiber airframe with a layer of epoxy adhesive and a layer of epoxy primer on the stainless steel Click Bond.

Another solution to galvanic corrosion that we utilize is careful material selection. The titanium we use in the firewall heat shield has an electrode potential very close to carbon fiber so it has very little potential for galvanic corrosion with carbon fiber.

In areas that we cannot use titanium alloys, we use stainless steel alloys. Stainless steel is a good second option when titanium cannot be used.

Instead of changing the metal alloy, it is also possible to shift the material selection away from carbon fiber and use a non conductive plastic. One example of this is the 3D printed Nylon cooling inlets on the engine.

The honeycomb sandwich panels we use to create the fuselage bulkheads in the DarkAero 1 use aluminum honeycomb cores. Another option instead of aluminum is aramid or Nomex honeycomb cores.

One solution that we do not use in the DarkAero 1 but is still a possible option is isolating the entire assembly to prevent any electrolyte bridge from forming.

00:00 Intro
00:48 What is galvanic corrosion?
01:45 Galvanic Corrosion Mechanisms
05:44 Solution 1: Fiberglass Layer
06:34 Solution 2: Paint Layer
07:10 Solution 3: Adhesive Layer
07:50 Solution 4: Titanium
08:22 Solution 5: Stainless Steel
08:58 Solution 6: Plastics
09:45 Solution 7: Aramid Honeycomb
10:47 Solution 8: Electrolyte Barrier
11:25 Solution 9: Do Nothing!
11:57 Outro

If you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage.

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