The salt spray settling rate in a salt spray corrosion test chamber refers to the amount of salt solution that settles on a surface per unit area over time. This parameter is critical in determining the effectiveness and consistency of the test, as it influences both the density and uniformity of the salt mist. In addition to the corrosive effect of chloride ions, oxygen diffusion within the liquid film on the metal surface also plays a significant role in the corrosion process.
Smaller salt spray particles have a larger surface area, which allows more oxygen to be adsorbed, thereby increasing the overall corrosivity. In nature, over 90% of salt particles have a diameter of 1 µm or less. Research shows that when the particle size is around 1 µm, the amount of oxygen adsorbed on the surface balances with the dissolved oxygen inside the particle. Further reduction in particle size does not significantly increase oxygen adsorption.
If the oxygen in the liquid film remains stagnant, the metal will corrode quickly, and the oxygen level in the film drops rapidly, slowing down the reaction. However, if the liquid film is continuously refreshed, the corrosion process can continue. The rate at which this liquid film is renewed increases with a higher salt spray settling rate. If the settling rate is too low, the renewal of the liquid film is insufficient, which can affect the corrosion process.
When the sedimentation rate is below 0.3 mL/80 cm²·h, the corrosion rate increases as the settling rate rises. This is because the liquid film becomes thinner, allowing oxygen to reach the cathode surface more quickly, thus accelerating the corrosion process until it stabilizes. However, when the settling rate exceeds 1.2 mL/80 cm²·h, the liquid film thickens, and oxygen diffusion becomes slower due to increased distance. As a result, the corrosion rate no longer increases significantly.
Therefore, maintaining a moderate salt spray settling rate ensures stable corrosion rates and reproducible test results. It is generally recommended to keep the settling rate between 1 and 2 mL/80 cm²·h to ensure accurate and consistent outcomes in salt spray corrosion testing.
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