This post turned up in a list I subscribe to. Its about wheel sets, but applies to our track, too.
—paste—
I don’t know what manufacturing processes IM and Jay Bee use, but brass bar
stock is not porous in the normal sense - at least not to the level of
magnification of the electron microscopes I have used. Its problem is that
common brass alloys contain about 40% zinc. At the microscopic level, the
zinc exists as separate islands of metal in the copper matrix. It does not
dissolve as salt dissolves in water. At content over (if my memory is
correct) 15% the zinc forms a continuous phase - it’s all pretty much linked
together. When exposed to a conductive liquid (sea water or bodily fluids)
the zinc oxidizes in preference to the copper. This is termed galvanic
corrosion. The zinc eventually dissolves, leaving behind a weak copper
sponge. I have been a boat builder, and just as in orthopedics, you never
use brass (or stainless steel) below the waterline of a vessel intended for
salt water service or contact with bodily fluids.
In normal use in our models, brass will not deteriorate into a sponge.
However the zinc will oxidize and deposit a non-conductive coating of zinc
oxide all over the surface. Nickel plating will prevent this problem -
until it wears off. I’m having all sorts of problems upgrading and
installing DCC in an old Akane model with worn drivers. Nickel silver is
actually a copper nickel zinc alloy with 15 to 25% nickel. If the zinc is
held below the limit where it is a continuous phase, corrosion is limited to
the small amount exposed at the surface. This wears off and you have a
conductive copper/nickel surface. Unless there is a couple percent of lead
in the alloy nickel silver is a pain to machine (I’ve not been able to find
a source of a free machining grade nickel silver), thus the preference of
some manufactures to use powdered metallurgy techniques.