Well I did inquire about the aluminium with the engineers, their reply was "we specifically avoid aluminum contact with water".
Sounds like short of coating the water jackets with glyptol, there's no stopping the process entirely.
I wonder if you could substitue silicone
oil or transformer
oil for the coolant? We used silicone
oil for dummy load cooling in the Navy. Ain't cheep at $40 a gallon but it's rated for around 400deg.
I'll see if I can find more info about it, this would eliminate the corrosion and barring external contamination would be perminant. The silicone oil is about as inert as you can get so there shouldn't be any gasket/seal issues.
I've been doing some digging and it appears that
Amsoil has a coolant that is much more aluminum friendly than the glycol / organics. They claim near 0 material loss:
http://www.amsoil.com/storefront/ant.aspx
I'm also wondering where the
zinc from the electrodes ends up???