Study of galvanic corrosion and mechanical joint properties of AZ31B and carbon-fiber–reinforced polymer joined by friction self-piercing riveting

A new testing methodology was developed to quantitively study galvanic corrosion of AZ31B and thermoset carbon-fiber–reinforced polymer spot-joined by a friction self-piercing riveting process. Pre-defined areas of AZ31B in the joint were exposed in 0.1 M NaCl solution over time. Massive galvanic corrosion of AZ31B was observed as exposure time increased. The measured volume loss was converted into corrosion current that was at least 48 times greater than the corrosion current of AZ31B without galvanic coupling. Ninety percent of the mechanical joint integrity was retained for corroded F-SPR joints to 200 h and then decreased because of the massive volume loss of AZ31B.