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Ford is fighting this process by electrocoating the aluminum panels to electrically and physically isolate the metals, and by using new coatings on all body bolts. To test the long-term durability of these kinds of joints, engineers normally bathe body panels in a saltwater spray during a hot/cold environmental cycle—this encourages the formation of iron oxide. But with aluminum that was just too slow. So they switched to a corrosive acid bath and found that tweaking the metallic coating on the bolts protected the metal admirably.

http://www.popularmechanics.com/car...-tested-its-new-aluminum-f-150-16682803/


There has been a lot of work done to electrically isolate and/or protect aluminum body and frame components. The TT Roadster I had a few years ago had an aluminum chassis and mostly aluminum body. Audi designed the car with a steel rear section to achieve a 50/50 balance and pioneered a method to connect the steel and aluminum frame/body sections rigidly and protect from galvanic corrosion.

I'm sure Ford has done their homework.


Jake Kohl