Validation of predictive model for galvanic corrosion under thin electrolyte layers: An application to aluminium 2024-CFRP material combination

•Set-up developed for galvanic corrosion model validation under very thin electrolyte.•Polarisation data under thin electrolytes acquired for AA2024 and CFRP.•Total current modelled and validated for variable film thickness and concentrations.•Current density and potential distribution on the electrodes were modelled.

An experimental setup was developed for the validation of a finite element model (FEM) for simulating galvanic corrosion occurring under very thin electrolyte for bi-material combination composed of aluminium AA2024 and carbon-fibre reinforced polymer (CFRP). The validation approach is explained and the results obtained are presented. The main outcomes of the model are electric current density and potential distribution on the electrode surface. Good agreement has been obtained between measured and modelled data. Further parameter studies are discussed to show the effect of different physical properties of the electrolyte on corrosion rates and total current changes in the materials involved.