Material Selection: Prioritize metal combinations with electrode potential differences <50mV; avoid direct contact between dissimilar metals with excessive potential differences.

Isolation: Install insulating gaskets, sleeves, or coatings at contact interfaces to break galvanic current paths.

Cathodic Protection: Apply sacrificial anodes (e.g., zinc, magnesium alloys) or impressed current protection to the anode metal to suppress corrosion.

Coating Protection: Apply anti-corrosion coatings to both metals, with emphasis on protecting the anode.

Material Selection: Use pitting-resistant materials such as molybdenum/ nitrogen-containing stainless steels (e.g., 316L, 2205 duplex steel) or titanium alloys.

Environment Control: Reduce chloride ion concentration in the medium, control temperature and pH, and add corrosion inhibitors.

Surface Treatment: Keep the surface clean to avoid deposits; passivate the surface to improve passive film stability.

Inspection & Maintenance: Regularly use ultrasonic or eddy current testing to detect pit depth and perform timely repairs.

Design Optimization: Avoid dead spaces and crevice structures; use butt welding instead of lap welding and fully enclosed flanges.

Sealing Improvement: Use non-absorbent, non-leaching sealing materials (e.g., PTFE) to prevent media from entering crevices.

Maintenance: Periodically flush and clean crevice areas to remove deposits and residual media.

Material Selection: Use crevice-corrosion-resistant alloys or apply heavy anti-corrosion coatings to crevice-prone areas.

Coating Process: Use dense, well-adhered, pinhole-free coatings; strictly perform surface pretreatment (derusting, degreasing, phosphating).

Defect Control: Avoid coating scratches or blisters; repair any damage immediately.

Environment Control: Reduce ambient humidity, avoid high-humidity and high-salt environments, and minimize moisture penetration.

Alternative Solutions: Use electroplating, thermal spraying, or other more durable surface treatments for critical components.

Material Improvement: Use low-carbon (≤0.03%) or ultra-low-carbon stainless steels, or add stabilizing elements like titanium or niobium (e.g., 321, 347 stainless steels).

Heat Treatment: Solution treat austenitic stainless steels to eliminate intergranular precipitates; avoid the sensitization temperature range (450–850°C).

Welding Control: Use low-heat-input welding processes and perform post-weld solution or stabilization treatments.

Surface Passivation: Perform pickling and passivation on finished parts to restore surface corrosion resistance.

Metallurgical Control: Use ingots with uniform structure and low impurity content; optimize the rolling process to reduce laminar segregation.

Surface Protection: Apply anti-corrosion coatings or anodic oxidation to block corrosive media from penetrating between layers.

Stress Control: Avoid residual processing stresses; perform post-processing stress relief to prevent stress-accelerated interlayer corrosion.

Inspection: Use ultrasonic or penetrant testing to detect hidden delamination defects at an early stage.

Stress Relief: Reduce or eliminate residual tensile stress through processes such as stress relief annealing or shot peening.

Material Selection: Choose alloys resistant to stress corrosion cracking in the target medium, e.g., titanium or nickel-based alloys in chloride environments.

Environment Control: Remove sensitive components (e.g., chloride ions, sulfides) from the medium and add corrosion inhibitors.

Design Optimization: Avoid stress concentration areas; use rounded transitions to reduce stress concentrations.

Cathodic Protection: Apply cathodic protection to the component to control potential within a safe range and suppress cracking.