What lives in washing machines and eats aluminium alloy?

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Discussion Overview

The discussion revolves around the phenomenon of corrosion in washing machines, particularly focusing on the interaction between aluminum alloys and steel components. Participants explore potential causes for the disintegration of aluminum parts, including electrolytic corrosion and design considerations, while examining the implications of local water chemistry and material choices.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant suggests that the washing machine's failure may be due to it becoming a "big battery," with the steel drive shaft embedded in the aluminum drive bracket.
  • Another participant proposes that electrolytic corrosion could be a plausible explanation, especially under high temperatures and alkaline conditions typical of washing powders.
  • Concerns about the "cheapness" of materials used in the washing machine are raised, with implications that this may contribute to design failures.
  • A suggestion is made to investigate local water chemistry, as dissolved minerals and gas content could influence corrosion processes.
  • One participant notes that corrosion is common when aluminum is bolted to steel, particularly along grain edges, referencing experiences from the cable industry.
  • Another participant emphasizes the need for electrical isolation between dissimilar metals to prevent corrosion, mentioning potential solutions like plastic washers or specialized coatings.

Areas of Agreement / Disagreement

Participants express multiple competing views regarding the causes of corrosion and the implications of material choices, indicating that the discussion remains unresolved.

Contextual Notes

Participants highlight the importance of local water chemistry and the potential for design flaws, but there are no definitive conclusions about the primary cause of the observed corrosion.

marcophys
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The washing machine stopped spinning, so I dismantled it.
Here's what I found:



I'm thinking it might have become a big battery, as the steel drive shaft was embedded in the alloy drive bracket, which in turn had 6 studs bolting it to the stainless steel drum.
It was all enclosed in the sealed water drum.

What I find interesting is the extent of the disintegration.
Also interesting is the design failure.
 
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Electrolytic corrosion sound plausible. Add high temperatures, high concentrations of ions (increasing water conductivity) and alkaline conditions (typical in many washing powder recipes) and it is a disaster waiting to happen.
 
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Add in the 'cheapness' factor...
 
ebos said:
Add in the 'cheapness' factor...

Or perhaps it was designed to fail.
 
You might want to try to get a report on the local water chemistry. (This is probably available from some town/county agency or somesuch). Dissolved minerals, gas content, &c could be playing a meaningful role in facilitating this process.

diogenesNY
 
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Completely normal for aluminum bolted to steel. The corrosion is concentrated along grain edges, so the aluminum disintegrates. I saw a lot of this working in the cable industry along the California coast. The cases for amplifiers were aluminum and the connectors steel. After a couple years in the salt spray, the case would fall apart when you tried to remove a connector.

I think I recognize the washing machine. A friend had one fail like that and the hub was caked with residue from the powdered detergent she used.
 
dschlink said:
Completely normal for aluminum bolted to steel.
Yeah -- isn't this just a standard case of what happens if you join dissimilar metals? I.e., according to the Galvanic series. The aluminium needs to be electrically isolated from the steel somehow. Sometimes plastic washers can help. There's also some paint-on goop available in marine supply stores, intended for essentially the same problem in boats, where you often want to use SS fasteners between Al sections.
 

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