Abstract: Zn-Al couple's galvanic coeeosion was a serious problem in acdic ainc sulfate solution .In this paper, a new pretreatment or a coating for Al was developed and tested to protect the Al effectively form corrosion when connected to pure Zinc at electroplating potential,and exposed to an acdic sulfate solution.Corrosion measurement techniques(Galvanic corrosion and DC)were used to investigate galvanic corrosion between Al cathode and Zn anode.It was found out that Al alloy purity and electroplating potential have a large effect on galvanic corrsion between Zn-Al couples.EIS,salt spray test and immersion test were performed to evaluate the method for Al cathodes in zinc electrolyte,BTSE silane pretreatment and polyurethane coating displayed better corrosion protection.Calculation showed the Al dissolution rate is small enough for Al cathode to be used in zinc plants.BTSE treatment or BTSE plus polyurethane coating has the best corrosion performance,and willprotect the Al cathode effectively in zinc electrolysis

Key words: Al-Zn couple, galvanis corrosion silane pretrment