Effect of Propylene Glycol Coolant pH on the Galvanic Corrosion Behavior of 6061 Aluminum Alloy/304 Stainless Steel.

6061 aluminum alloy is lightweight and has good thermal conductivity, while 304 stainless steel possesses excellent mechanical properties and corrosion resistance; both have broad application prospects in cooling circuits. Propylene glycol coolant shows great potential in liquid cooling systems due to its low toxicity and good antifreeze properties. However, during operation, galvanic corrosion may occur when the two metals come into direct contact within the coolant, thereby threatening system safety and service life. This study focuses on 6061 aluminum alloy, 304 stainless steel, and their galvanic couples. Electrochemical testing, SEM, 3D confocal microscopy, and XPS were used to systematically investigate their self-corrosion and galvanic corrosion behavior in propylene glycol coolant at pH values of 4.8, 6.8, and 8.8. The results indicate that 6061 aluminum alloy is more sensitive to pH changes; its corrosion resistance first increases and then decreases as pH rises, with the least corrosion occurring at pH = 6.8 and the most severe at pH = 4.8. 304 stainless steel exhibited lower corrosion rates at pH 6.8 and 8.8, but corrosion significantly worsened at pH 4.8. For the 6061 aluminum alloy/304 stainless steel couple, the galvanic current first decreased and then increased with rising pH, while the galvanic potential first increased and then decreased. The 6061 aluminum alloy consistently acted as the anode, and the 304 stainless steel consistently acted as the cathode, with the highest sensitivity to galvanic corrosion observed at pH 4.8. XPS analysis shows that under different pH conditions, the corrosion products of 6061 aluminum alloy are Al(OH)3 and Al2O3, while the main components of the passivation film on 304 stainless steel remain unchanged.