Galvanic corrosion continues to be a major challenge in designing reliable multi-material structures for modern e-mobility systems. This work aims to better understand, simulate, and validate how galvanic corrosion progresses in both coated and uncoated automotive alloys particularly in steel–aluminum–copper combinations and emerging composite materials. The study examines the underlying electrochemical behavior using the galvanic series, Butler–Volmer kinetics, and experimentally measured parameters that feed into advanced computational models. Using COMSOL Multiphysics, we develop 2D and 3D steady-state electrochemical simulations that solve Laplace’s equation with nonlinear Neumann boundary conditions. These models capture how electric potential and current densities distribute across anode–cathode interfaces, allowing us to explore the impact of coating integrity, defects, and geometric features on galvanic driving forces. To ensure the models reflect real-world behavior, Scanning Vibrating Electrode Technique (SVET) experiments are performed on both lab-scale samples and actual automotive components under realistic environmental conditions. By comparing coated and uncoated systems, we evaluate coating performance, identify degradation pathways, and quantify long-term corrosion behavior. Overall, this research delivers a predictive, experimentally validated framework for assessing galvanic corrosion risks in multi-material automotive structures. The findings support smarter material selection, improved coating strategies, and more corrosion-resilient component designs tailored for next-generation applications.
