Galvanic Corrosion Susceptibility Analysis and Mitigation strategies in Automotive Battery Packs

As electric vehicles continue to revolutionize transportation, ensuring the reliability of their powertrain systems and battery packs has become a critical focus. One key challenge is galvanic corrosion, which occurs when dissimilar metals in contact are exposed to an electrolyte, such as seashore moisture or road salt used in snow or ice zones. This corrosion can weaken structural components, compromise electrical conductivity, and reduce the lifespan of critical systems. Common areas at risk include metallic joints within battery enclosures, busbars, cooling systems, and electrical connectors. Environmental factors such as high humidity and temperature fluctuations further amplify the issue, making it a pressing concern for manufacturers. This paper aims to systematically identify critical galvanic joints within electric powertrain systems and battery packs and provide effective strategies to mitigate corrosion risks. Preventative measures include choosing compatible materials with similar electrochemical properties, applying protective coatings, and utilizing dielectric barriers to isolate metals. Design optimizations, such as minimizing contact surfaces and improving drainage, can reduce the accumulation of electrolytes, while sealed enclosures and humidity management systems offer additional environmental protection. Regular maintenance and inspections are essential to detect early signs of corrosion and prevent long-term damage. By integrating these strategies into manufacturing and design workflows, automakers can enhance the durability, safety, and overall performance of electric powertrain systems ensuring they meet the growing demands of sustainable mobility.