G.J.
Ayton 2009
Differential Aeration Corrosion
Introduction
Corrosion of metals is observed occurring in
very small spaces i.e. crevices and under dirt
and debris deposited on the surface. The
openings are in the region of a few
thousands of an inch or less in width,
openings above approximately 1/8th of an
inch do not experience such corrosion.
Fig 1 – Crevice (Differential Aeration) corrosion of a
silver heating coil.
In Fig 1.1 the heating coil is submerged in
the liquid it is heating. Solids in the liquid
tend to deposit on the heating coil. The
liquid provides the electrolyte and oxygen
required for the corrosion.
Problem Analysis
Initially Oxidation and Reduction reactions
occur uniformly across the material surface,
including within crevices/under deposits.
Charge conservation is maintained as every
electron formed from the Oxidation (anodic)
reaction is immediately used to supply the
Reduction (cathodic) reaction. Also for every
hydroxyl ion (4OH-) produced by the
Reduction reaction there is a positive metal
ion created by the Oxidation reaction (M+).
When the O2 dissolved in the electrolyte
under the deposit is depleted it cannot be
restored due to the restricted convection of
the electrolyte into the region. As a result,
O2 reduction ceases – this itself does not
cause any change in corrosion behaviour;
the crevice area is very small compared with
the external area so the rate of reduction
remains virtually unchanged. This lack of O2
has an indirect influence, although O2
reduction no longer occurs, the metal
dissolution continues producing the Metal+
University of Hertfordshire - School of Science, Technology and Creative Arts
Corrosion Case Studies
ions, making the crevice region anodic. The
resulting excessive positive charge is
balanced by ‘migration’ of chloride ions. The
increased concentration of metal chloride in
the crevice produces an insoluble hydroxide
and a free acid (hydrogen chloride, H+Cl-,
solution in H2O).
Fig 2 – Migration of Cl ions
The chloride and hydrogen ions accelerate
the oxidation reaction that corrodes the
metal. This further oxidation increases Cl
migration which in turn further accelerates
the metal corrosion (it is an ‘autocatalytic’
process). The rate of O2 reduction on the
surfaces outside the crevice/deposit area
increases as oxidation increases in the
crevice cathodically protecting these
surfaces. Differential Aeration Corrosion will
take 6 months to a year to begin but
commences at an increasing rate once
started
Solution
1) Use welded butt joints.
2) Close crevices by continuous welding,
caulking or soldering.
3) Inspect and remove deposits on
surfaces frequently – this would be
the right choice for this case.
4) Use solid, non-absorbent gaskets
such as Teflon.
Reference:
M.G Fontana, Corrosion Engineering, 3rd ed.,
McGraw-Hill, New York, p39-44, 1986.
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