How To Fix Corroded Battery Contacts

Why do terminals and contacts patinate and corrode?

Most naturally occurring metals are oxidised ore—they try to return to this state of permanent oxidation when used in their metallic state. This process is called corrosion. What’s interesting, the more energy is used during the technological process of turning ore (persistent bound form) into its metallic form (unstable free state), the more easily and quickly it will corrode when used.

Corrosion affects surfaces of metallic materials. The process requires electrolyte (moisture, water with dissolved gases and chemical compounds), and a depolariser (oxygen). Electrolyte and depolariser are fundamental external factors that cause corrosion.

The corrosion process is also determined by a metal’s chemical composition, state of its surface, and stress formed during heat treating—all of these are internal factors. Every material’s internal corrosion factors are determined mostly by crystal structure, containing atoms of elements with specific properties and valence electron numbers. Susceptibility to corrosion is also determined by the purity of a material—the less pure the alloy and the lower its electrochemical potential, the higher the probability of corrosion.

Patination affects both non-galvanised and galvanised elements that are not protected against zinc oxidation. Zinc is highly reactive in acidic and alkaline environments. Unprotected zinc surfaces coming into contact with electrolyte are affected by the so-called white rust (wet storage stain). In normal weather conditions, zinc creates zinc oxide, zinc carbonate, and zinc hydroxide that manifest as easy-to-clean white build-up. This build-up prevents corrosion of metal elements, but also dramatically reduces their electrical conductance.

Build-up on vehicle battery terminals may also be caused by unsealing of the battery or its sulfation—the build-up is slightly darker in those cases. Patination can also become an issue when voltage regulator gets damaged, causing overcharging of battery, boiling of electrolyte, and increased emission of gases that react with terminals and, consequently, patinates them. If that happens, you need to properly clean the vehicle battery terminals.

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Why is the Positive (Red) Terminal of my Car Battery Corroded?

If you see corrosion or build-up on the positive terminal of your car battery it will generally have a bluish or greenish color to it.  This is due to copper sulfate as the product of a chemical reaction between the copper in the terminal clamp, moisture in the air, lead in the battery post, sulfuric acid in the battery, and excess electricity.  

The primary reason corrosion will occur on the positive terminal is due to your battery overcharging.

The main culprit for this would be a faulty voltage regulator or some other aspect of your alternator, which is designed to keep your battery properly charged as you drive.  If it is perpetually overcharging, your battery is also outgassing and losing water out of the electrolyte solution due to heat and evaporation.

How to Prevent Battery Corrosion

After removing the corrosion from your battery, you can use these tips that will prevent it from happening again:

• Make sure there is a good connection between the battery post and terminal. To achieve this, battery terminals must be in good shape. A terminal should have a clean and smooth surface where it meets the post, and you should be able to tighten it up. If not, replace the battery terminal with a new, high-quality one.
• Check the battery water level once a month and top it up if needed. Use only distilled water for this purpose and be careful not to overfill the battery. Also, check the charging state of your alternator using a multimeter. In most cases, readings above 15 volts are a sign of a bad voltage regulator.
• Apply paste coatings and sprays to the battery posts. They will provide an additional layer of protection. An alternative are felt washers, which go between the terminal and the plastic battery surface. These fiber pads are soaked with a special chemical that neutralizes acid fumes.

But wait… what causes battery cables to corrode?

As mentioned above, batteries are filled with sulfuric acid. When your motor heats up and cools down, it causes your battery (and the sulfuric acid inside it) to do the same, resulting in the creation and release of hydrogen gas. These gasses react to particles around your battery terminals and create the corrosion you see. You’re more likely to see extreme corrosion in the summertime when it’s hotter outside.

Does a corroded battery need to be replaced?

Sometimes, a corroded battery cannot be sufficiently cleaned. Or, it has other issues that indicate it’s time for a replacement. When inspecting your battery, be sure to note the condition of the case itself. If it’s leaking or bloated, don’t bother with trying to clean the corroded terminals and cables. Instead, head to your local auto repair shop for a new car battery.

Beyond excessive corrosion and leaking or swelling of the battery case, here are a few other symptoms that indicate it’s time for a new battery instead of cleaning or repair of the old one:

• Difficulty starting the vehicle – the engine crank is slow and the car has difficulty starting or won’t start at all.
• Check engine light is on – this can occur for multiple reasons, but can also appear when the battery is weak and ready to call it quits.
• Low battery fluid – look at the side of the battery. There is often a clear window through which you can see the battery fluid level. If it’s below the lead plates, talk to your mechanic about battery testing or replacement.
• Age – if your battery is greater than three years old, it’s on borrowed time.

Conclusion

If you are having trouble starting your car in the morning, the first thing to check should be battery terminals. Corrosion can occur on any car battery, shortening its lifespan and preventing proper operation. However, as you have seen in this article, removing and preventing battery corrosion is a simple job.

If you are having trouble starting your car in the morning, the first thing to check should be battery terminals. Corrosion can occur on any car battery, shortening its lifespan and preventing proper operation. However, as you have seen in this article, removing and preventing battery corrosion is a simple job.

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By CarRoar

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Things You’ll Need

Disconnecting Your Car Battery Safely

• Rubber, nitrile, or neoprene work gloves
• Safety goggles
• Wrench
• Terminal spreader

Removing Car Battery Corrosion with Baking Soda

• 1 cup (240 mL) water
• 1 teaspoon (4.6 g) baking soda
• Toothbrush or battery terminal brush
• Clean, dry rag
• Water hose or spray bottle
• Petroleum jelly

Cleaning Corrosion on Alkaline Battery Contacts

• Safety goggles
• Rubber or nitrile work gloves
• White vinegar or lemon juice
• Glass or plastic bowl
• Cotton swabs
• Small blade or fiberglass pen
• Silicone grease or petroleum jelly

What causes battery cable and terminal corrosion?

If you remember from chemistry class, chemical reactions often result in the desired action or product. But, they can also lead to the formation of byproducts. In car batteries, we see that in the form of corrosion.

As your vehicle heats and cools, so does the battery. During this process, hydrogen gas is released through the battery’s vents and mixes with particles around the battery itself. This mixture builds up over time and is the corrosion we most often see on battery terminals or cables.

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