Predicting the effect of droplet geometry and size distribution on atmospheric corrosion

A new approach is proposed to numerically predict and study atmospheric corrosion for ranging droplet size distributions and the influence of the droplet geometry. The proposed methodology allows for a corrosion prediction based on observed droplet size distributions and droplet contact angles. A mechanistic finite element model, including oxygen transport and Butler-Volmer kinetics, is solved in order to obtain the current density as a function of the droplet geometry. This is done for a range of both droplet radii and contact angles. The computed corrosion current densities are then used as input for imposed droplet size distributions. This allows for a calculated material loss estimation for different distributions and electrolyte configurations and shows the extent of the impact of the droplet size distribution on atmospheric corrosion. •Numerical approach to evaluate corrosion under given droplet size distributions.•Applying steady-state, FEM single droplet model with imposed droplet distribution.•Evaluating effect contact angle and average droplet radius on corrosion.•For the considered distributions, surface area is the critical parameter.