Fallon
Super Member
Aluminum, magnesium, & zinc provide galvanic protection for steel. They get eroded before the steel. Galvanic Reaction: Incompatible Metals Responsible for Corrosion has a chart showing which materials are on what end if the galvanic spectrum.OP here- Thanks, guys.
I thought it might be easy and cheap to buy tubing for this at any local muffler shop. (This project is just a whimsical experiment.) Since asking for your opinions, I found a major distributor of exhaust system components online that describes their tubing as aluminized. (Aluminum coated) Direct food contact with aluminum is controversial. Also wondering if "aluminized" is conflated with "galvanized", which is actually, a zinc coating. I heard that welders avoid galvanized steel for health reasons and doubt if galvanize would be used on such a commonly welded product.
Stainless tubing is almost perfect but probably only available from online suppliers. No matter how small the quantity, most of my online orders for steel end up at over $50. I just spent 20 minutes trying to get a shipping estimate for SS tubing online that required my zip code but wouldn't allow me to enter it in their little box. Much to be liked about brick and mortar.
Zinc has a boiling point of 1670f, aluminum boils at 4478f. The melting point for zinc is a bit lower than aluminum as well & a fair bit under the boiling point. So in a hot car exhaust, the higher melting point of aluminum will make it less likely to melt/burn off while still providing galvanic protection. The fact zinc boils so low combined with its toxic fumes makes it hard to weld & a bad idea to weld (without good air purification).