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Atmospheric corrosion of metals is the most common type of corrosion which has a significant impact on the environment and operational safety in various situations of everyday life. Some of the common examples can be observed in land, water and air transportation systems, electronic circuit boards, urban and offshore infrastructures. The dew drops formed on metal surface due to condensation of atmospheric moisture facilitates corrosion as an electrolyte. The corrosion mechanisms under these droplets are different from classically known bulk electrolyte corrosion. Due to thin and non-uniform geometric thickness of the droplet electrolyte, the atmospheric oxygen requires a shorter diffusion path to reach the metal surface. The corrosion under a droplet is driven by the depletion of oxygen in the center of the droplet compared to the edge, known as differential aeration. In case of a larger droplet, differential aeration leads to preferential cathodic activity at the edge and is controlled by the droplet geometry. Whereas, for a smaller droplet, the oxygen concentration remains uniform and hence cathodic activity is not controlled by droplet geometry. The geometry of condensed droplets varies dynamically with changing environmental parameters, influencing corrosion mechanisms as the droplets evolve in size. In this review, various modelling approaches used to simulate the corrosion under droplet electrolytes are presented. In the efforts of developing a comprehensive model to estimate corrosion rates, it has been noted from this review that the influence of geometric evolution of the droplet due to condensation/evaporation processes on corrosion mechanisms are yet to be modelled. Dynamically varying external factors like environmental temperature, relative humidity, presence of hygroscopic salts and pollutants influence the evolution of droplet electrolyte, making it a complex phenomenon to investigate. Therefore, an overview of available dropwise condensation and evaporation models which describes the formation and the evolution of droplet geometry are also presented from an atmospheric corrosion viewpoint.

The Devanathan-Stachurski-cell is the most commonly used electrochemical technique for the investigation of the hydrogen trapping properties of a material. In this set-up, a flux of hydrogen atoms diffuses through a metal membrane under study. The atoms are subjected to the heterogeneities naturally present in the lattice of the metal, acting as traps. This matter influences the diffusion of hydrogen, which is strongly microstructure related. In this paper, we apply a numerical model to different iron-alloys to determine the hydrogen trapping parameters characterizing the materials. We highlight the complexity of the hydrogen trapping mechanism which needs to be further investigated.

Atmospheric corrosion is a complex problem, essentially an electrochemical process under confined thin electrolyte layers. Predictions require better mechanistic models to understand the underlying fundamental subprocesses on a microscopic level. We developed a mechanistic multi-ion transport and reaction model (MITReM) that considers time-dependent accumulation of concentrations in thin (NaCl) confined electrolyte layers. The model predicts local concentration and electrolyte potential distributions, from which corrosion rates are derived. Simulations in the confined dynamic film show that the chloride accumulation causes a deviation from the reverse proportionality of the corrosion current with the film thickness below films of 10 μm . The oxygen distribution and local corrosion current densities demonstrate that the contribution of the edge effect decreases for thinner electrolyte layers. The influence of the electrode geometry on the current density also decreases with decreasing film thickness. These qualitative insights are essential for the development of atmospheric corrosion prediction tools and aid in the design and interpretation of electrochemical techniques for confined thin film electrolytes.

The electrolyte film thickness condensation and evaporation is an important parameter for complexity of atmospheric corrosion. Atmospheric corrosion rate of zinc at the west coast of Singapore was measured for one year using an electrical resistance monitoring system. The analysis of the data reveals that significant corrosion rates only occur at specific hours on dry days. The beginning of this period corresponds to falling temperature and rising relative humidity resulting in the formation of a film of moisture on the zinc surface and the end corresponds to a point that this film dries as the temperature increases. This finding allowed the drying rate of the moisture film to be estimated for input into a moving boundary simulation model of the galvanic corrosion in scratched and zinc coating samples. The simulation results showed that the maximum corrosion rate occurs at electrolyte thickness of about 8 μm. Moreover, the simulation suggested that cut-edge is a more harmful defect than scratch, which was confirmed by the appearance of iron corrosion products on atmospheric exposed cut-edge samples whereas scratched samples were not corroded after one week of exposure. Finally, moving boundary simulation allowed to predict the changes to the geometry of the corroding electrodes.