Re: brass prop + alum boat
Just dug out my Materials Application, Dissimilar Metals chart.
You are correct in what you said. Al is Group I while Copper and alloys (Brass-Bronze) are over in Group IV along with Stainless Steel. Obviously you know that you don't mix groups if you can help it, but adjacent groups are somewhat tolerable, and the notes say "in contact with" is where the problems occur.
I know you are talking about salt water being the vehicle where the migration will take place; hence "in contact with"; but at a highly reduced rate due to the low conductivity of the water.
Butttttttttttttt Alum alloys, which most boats are made from to get 5052 T6 grade of alum for strength, is an alloy and Zinc and Al alloys show up in Group II, along with Stainless Steel (SS is in all groups but I).
In Group III we also find Zinc along with SS.
So, a strategically placed zinc bar, like between the prop and hull (assuming you are talking about an inboard setup, would protect the weaker metal. Needs to be in contact with the alum so you will need some SS screws to attach it and then seal the screws on the inside of the hull.
The prop will mount to your SS shaft so that's fine, as is your brass/bronze thru hull bushing and your SS shaft.
More buttttttttttttttts. For years and years, brass props were used on ss drive shafted, alum housing outboards, especially at OMC. I know that the Merc trim tab has been zinc for years and years. I think Merc I/O's also had one on the outer transom mounting bracket long before they added it to their OB's.
HTH
Mark