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p,.entry-content[class] li{font-size: 16px !important}.entry-content[class] table th,.entry-content[class] table td{font-size: 14px !important;padding: 11px 12px !important}.entry-content[class] .aobo-hero{padding: 30px 22px}.entry-content[class] .aobo-final-cta{padding: 26px 22px}.entry-content[class] .aobo-final-cta .aobo-btn{width: 100%}}\n<\/style>\n<section class=\"aobo-ht-ref ts-props\">\n<div class=\"aobo-wrap\">\n\n<div class=\"ts-hero\">\n<div class=\"ts-hero-top\">\n<div class=\"ts-kicker\"><span><\/span>Mold Steel | Corrosion | Water Channels<\/div>\n<h1 style=\"--h1-max:40px\">Crevice Corrosion in Mold and Die Steel<\/h1>\n<p>Crevice corrosion is the attack that happens in a gap too tight to see into and too open to keep dry. On a mold it shows up as a ring of pits under an O ring, a line of attack along a threaded plug, or a rash of pitting under a layer of rust. The steel in the cavity is fine. The steel in the gap is not. This page covers why an occluded geometry is more aggressive than an open surface, why stainless grades are the ones most often caught by it, and what removes the risk.<\/p>\n<\/div>\n<\/div>\n\n<div class=\"ts-tool-area\">\n\n<h2 class=\"ts-h2\">An occluded surface is a different environment<\/h2>\n<p class=\"ts-p\">Crevice corrosion happens where a wetted metal surface sits in close proximity to another surface. In real crevices the average separation, which the source calls the gap, is typically somewhere between 0.1 and 100 micrometres, and the gap is not uniform along its length. It is set by the points where asperities on the two surfaces meet, so the local separation varies along the crevice and can include patches of intimate contact. That is why a crevice prepared in a laboratory is an idealisation of the real thing, and why the nominal gap of a test specimen is only an average.<\/p>\n<p class=\"ts-p\">The consequence of the tight geometry is a transport problem. Inside the gap the solution cannot exchange freely with the bulk fluid, so the reactions that make up the corrosion cannot stay in balance with it. The anodic and cathodic reactions separate, dissolved species concentrate, the local pH shifts, and the changes are maintained rather than mixed away. The result is the signature appearance the source describes in its examples. Attack is accelerated under the crevice former and the fully exposed surface immediately outside it shows almost nothing, because that exposed surface is working as a cathode rather than dissolving. Attack inside the gap usually appears as uniform corrosion or as pitting, and in some cases it is thought to begin as metastable pits that coalesce into a broader front.<\/p>\n<p class=\"ts-p\">The rate is not constant. Crevice corrosion typically starts at a high rate and then slows as the occluded environment reaches a steady state against the conditions on the outside surface. It does not stop, though. The source puts the steady state range at 25 to 250 micrometres per year, which is one to ten mils per year, and that is a rate that will perforate a cooling channel wall given enough time and enough stops and starts.<\/p>\n<p class=\"ts-p\">The variables that decide how severe the attack becomes are not all geometric. The table below collects the ones the source identifies, with the direction of each effect, because several of them can be changed on an existing mold without touching the steel.<\/p>\n<div class=\"ts-table-wrap\" style=\"width:fit-content;max-width:100%\">\n<table class=\"ts-table\" style=\"min-width:1060px;\">\n<thead><tr><th>Variable<\/th><th>What it does<\/th><th>Direction<\/th><\/tr><\/thead>\n<tbody>\n<tr><td class=\"ts-type\">Gap between the two surfaces<\/td><td class=\"ts-safe\">The tighter the crevice, the more severe the attack. The source gives a typical average separation in real crevices of between 0.1 and 100 micrometres<\/td><td>Smaller gap makes it worse<\/td><\/tr>\n<tr><td class=\"ts-type\">Depth and length of the crevice<\/td><td class=\"ts-safe\">Together with the gap these two dimensions govern initiation and propagation, and they set how hard it is for the bulk solution to reach the inner surface<\/td><td>Longer and deeper makes it worse<\/td><\/tr>\n<tr><td class=\"ts-type\">Bulk pH<\/td><td class=\"ts-safe\">A more alkaline bulk solution tends to lengthen the time to initiation, because the aggressive anions take longer to concentrate enough to depassivate the metal<\/td><td>More alkaline delays it<\/td><\/tr>\n<tr><td class=\"ts-type\">Potential of the part<\/td><td class=\"ts-safe\">More anodic potentials exacerbate crevice corrosion. The potential can come from a dissolved oxidizer such as oxygen, chlorine or ozone, or from galvanic coupling to a more noble metal<\/td><td>Higher potential makes it worse<\/td><\/tr>\n<tr><td class=\"ts-type\">Temperature<\/td><td class=\"ts-safe\">Increased temperature is the clearest single accelerant, which is why it is the basis for the accelerated tests. Titanium alloys show no crevice corrosion below 70 C (158 F)<\/td><td>Hotter makes it worse<\/td><\/tr>\n<tr><td class=\"ts-type\">Flow through the crevice<\/td><td class=\"ts-safe\">Flow inhibits initiation, because it makes it harder for the aggressive environment to build up in the occluded region in the first place<\/td><td>Flow through it helps<\/td><\/tr>\n<tr><td class=\"ts-type\">Nickel, chromium, molybdenum and nitrogen in the alloy<\/td><td class=\"ts-safe\">All four raise resistance, and chromium, molybdenum and nitrogen are the potent ones with beneficial interactions among them<\/td><td>More of them is better<\/td><\/tr>\n<tr><td class=\"ts-type\">Fraction of the surface that is passive<\/td><td class=\"ts-safe\">Most of the surface has to be passive for crevice corrosion to matter at all, because the exposed area has to work as a net cathode to drive the attack inside<\/td><td>A passive surface is the precondition<\/td><\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<p class=\"ts-tcap\"><em>The variables the source identifies as controlling crevice corrosion, with the direction of each effect. Compiled from the critical factors and environment sections of the article.<\/em><\/p>\n\n<h2 class=\"ts-h2\">Where the crevices are on a mold<\/h2>\n<p class=\"ts-p\">Almost any engineered assembly contains places where two materials are, by design, held in close proximity, and a mold has more than most. A cooling circuit is a series of bores that have to be plugged, joined and sealed, and every one of those joints is a candidate. The table below sets out the configurations that matter on mold hardware, why each one retains electrolyte, and the countermeasure. The last row is the one that gets missed, because a deposit is itself a crevice former and a rust layer under a moulding can hold the aggressive solution against the steel for months.<\/p>\n<div class=\"ts-table-wrap\" style=\"width:fit-content;max-width:100%\">\n<table class=\"ts-table\" style=\"min-width:1060px;\">\n<thead><tr><th>Where it forms<\/th><th>Why electrolyte stays in it<\/th><th>What is done about it<\/th><\/tr><\/thead>\n<tbody>\n<tr><td class=\"ts-type\">Cooling channel wall next to a threaded plug or fitting<\/td><td class=\"ts-safe\">The thread is a long helical gap. Water sits in the root of the thread and stops moving, while the channel bore carries flow past it<\/td><td class=\"ts-safe\">Seal the plug with an O ring face rather than on the thread, and refresh the circuit between shifts<\/td><\/tr>\n<tr><td class=\"ts-type\">O ring groove and the face behind it<\/td><td class=\"ts-safe\">The groove is open to water on one side and closed on the other. The ring only seals at its contact line, not across the whole groove<\/td><td class=\"ts-safe\">Keep the groove clean and unpitted, and use a ring that is specified for the service temperature<\/td><\/tr>\n<tr><td class=\"ts-type\">Parting line and shut off faces<\/td><td class=\"ts-safe\">Two faces meet under clamping force and leave a gap in the range where a crevice can hold liquid after washing<\/td><td class=\"ts-safe\">Dry the faces after washing, and avoid water based release agents that pool on them<\/td><\/tr>\n<tr><td class=\"ts-type\">Insert seat and bolted joint faces<\/td><td class=\"ts-safe\">A bolted or shrunk in insert and its seat form a lap joint with capillary access to moisture<\/td><td class=\"ts-safe\">Seal the joint or make it continuous, and check the seat faces rather than only the cavity<\/td><\/tr>\n<tr><td class=\"ts-type\">Under a rust layer, scale or a polymer deposit<\/td><td class=\"ts-safe\">A deposit is its own crevice former. It shields the metal underneath from oxygen while the bulk fluid still reaches it at the edges<\/td><td class=\"ts-safe\">Remove deposits by a method that takes the layer off, not one that only loosens it<\/td><\/tr>\n<tr><td class=\"ts-type\">Between two different metals in the same circuit<\/td><td class=\"ts-safe\">The gap holds electrolyte and the couple supplies an elevated potential at the same time<\/td><td class=\"ts-safe\">Insulate the joint, or bring the potential back down by avoiding noble partners<\/td><\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<p class=\"ts-tcap\"><em>Crevice geometries that occur on molds and dies, why each one retains electrolyte, and the countermeasure. The geometries are the plant cases described in the source, applied to mold hardware.<\/em><\/p>\n\n<h2 class=\"ts-h2\">Why the stainless grades are the ones caught<\/h2>\n<p class=\"ts-p\">There is a precondition that explains the pattern of failures. For crevice corrosion to matter, the vast majority of the surface has to be passive, because the exposed area outside the gap has to serve as a net cathode to drive the high rate of dissolution going on inside it. A steel that is actively corroding all over does not develop a crevice problem, because it does not build the potential difference in the first place. Stainless steels are widely recognised as susceptible precisely because they passivate well, and the same is true of the nickel, titanium and aluminium base alloys that rely on passivation for their protection. A mold steel chosen for its corrosion resistance is therefore a candidate for crevice attack in a way a plain carbon steel is not.<\/p>\n<p class=\"ts-p\">Alloying helps, and it helps in a specific combination. Nickel and chromium additions raise resistance, and molybdenum and nitrogen raise it further, with chromium, molybdenum and nitrogen the potent ones and with beneficial interactions among the three. Titanium alloys are the most resistant of the families the source discusses, and even they are not immune. They show no crevice corrosion below 70 C (158 F), and alloying titanium with small amounts of molybdenum, nickel or palladium is reported to hold that resistance to almost 200 C (392 F) in a 10% ferric chloride solution. The practical reading for a mold is that where the operating temperature is well below the threshold for the grade in hand, the crevice may stay quiet, and where the circuit runs hot the same geometry that was harmless in a cool mold becomes an active site.<\/p>\n\n<h2 class=\"ts-h2\">Temperature, and the number to design against<\/h2>\n<p class=\"ts-p\">Increased temperature is the clearest single accelerant for crevice corrosion, which is why it forms the basis of the accelerated tests. Running a creviced specimen at a constant applied potential while the temperature is programmed upward gives a transition that is very sharp and reproducible, and the temperature at that transition is the critical crevice temperature. It is measured the same way as the critical pitting temperature, and it sits below it for the same alloy, because a crevice needs a lower temperature to become active than an open surface does. That ordering is the whole reason a mold with a gasketed joint can pit at a temperature where the cavity surface is quiet.<\/p>\n<p class=\"ts-p\">The other number worth having is the repassivation potential. It is determined by starting crevice corrosion deliberately at a high applied potential and then finding the highest potential at which the material can recover, and the source reports that when a properly measured repassivation potential is used, maintaining the open circuit potential of the part below it prevented any initiation out to at least three years in the test it cites. That is a stronger statement than a ranking, because it turns a laboratory measurement into an operating limit. Where a cooling circuit can be kept below that potential, the geometry stops being the deciding factor.<\/p>\n\n<h2 class=\"ts-h2\">How crevice corrosion is tested and ranked<\/h2>\n<p class=\"ts-p\">The standard route is a ferric chloride exposure, which concentrates chloride at a low pH and uses the ferric and ferrous ion couple to supply the elevated potential the mechanism needs. It becomes a crevice test rather than a pitting test when a crevice former is pressed onto the coupon. To make the result comparable between heats and between suppliers, the test is often run with a multiple crevice assembly, in which a castellated washer provides up to 20 possible sites for corrosion on each side of the coupon and a consistent torque is applied to several replicate samples. That gives a statistical basis for a comparison rather than a single observation.<\/p>\n<div class=\"ts-table-wrap\" style=\"width:fit-content;max-width:100%\">\n<table class=\"ts-table\" style=\"min-width:1000px;\">\n<thead><tr><th>Method<\/th><th>What it produces<\/th><th>How it works<\/th><\/tr><\/thead>\n<tbody>\n<tr><td class=\"ts-type\">Ferric chloride exposure with a crevice former<\/td><td>A pass or fail ranking between materials<\/td><td class=\"ts-safe\">A high chloride, low pH solution in which the ferric and ferrous ion couple supplies an elevated potential, with a washer pressed onto the coupon<\/td><\/tr>\n<tr><td class=\"ts-type\">Multiple crevice assembly<\/td><td>A statistical basis for comparing alloys<\/td><td class=\"ts-safe\">A castellated washer gives up to 20 possible sites on each side of the coupon, and a consistent torque applied to several replicate samples makes the results comparable<\/td><\/tr>\n<tr><td class=\"ts-type\">Electrochemical critical crevice temperature test<\/td><td>The critical crevice temperature, CCT<\/td><td class=\"ts-safe\">A constant positive potential is applied while the temperature is programmed upward, and the current needed to hold that potential is monitored until it rises sharply<\/td><\/tr>\n<tr><td class=\"ts-type\">Repassivation potential by a modified ASTM F 746<\/td><td class=\"ts-safe\">The highest potential at which the material repassivates<\/td><td class=\"ts-safe\">Crevice corrosion is initiated under controlled conditions at a high applied potential, then the potential is stepped down to find where the material recovers<\/td><\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<p class=\"ts-tcap\"><em>The test routes the source describes for ranking crevice corrosion resistance and for setting an operating limit. The repassivation potential determined this way is presented as an engineering design criterion rather than a screening number.<\/em><\/p>\n<p class=\"ts-p\">There is a direct relationship between crevice corrosion and pitting that is useful when reading a failure. A material and environment combination that causes pitting can also cause crevice corrosion, and the two share their electrochemistry, their occluded chemistry and their morphology. What differs is the threshold. If a grade is known to be marginal on pitting in a given chloride level, it will be worse in a crevice at the same temperature. The pitting side of the same mechanism is covered on <a href=\"https:\/\/aobosteel.com\/tool-steel-pitting-corrosion\/\">pitting corrosion in tool and mold steel<\/a>.<\/p>\n\n<h2 class=\"ts-h2\">What removes the risk on a mold<\/h2>\n<p class=\"ts-p\">The source puts the first measure before any material selection, and it is worth following that order. If electrolyte can be rigorously excluded from the gap, crevice corrosion is not possible, because one of the requirements for corrosion has been removed. That is a statement about geometry and about sealing, not about the alloy, and no change of grade achieves it. Where complete exclusion cannot be maintained, and in practice it usually cannot, the attack has to be managed rather than eliminated, which is what the measures below do.<\/p>\n<div class=\"ts-table-wrap\" style=\"width:fit-content;max-width:100%\">\n<table class=\"ts-table\" style=\"min-width:1020px;\">\n<thead><tr><th>Measure<\/th><th>Why it works<\/th><th>Where it applies<\/th><\/tr><\/thead>\n<tbody>\n<tr><td class=\"ts-type\">Remove the crevice instead of upgrading the material<\/td><td class=\"ts-safe\">If electrolyte can be rigorously kept out of the gap the mechanism has no requirement left, and no alloy change achieves the same result<\/td><td>First choice at the design stage<\/td><\/tr>\n<tr><td class=\"ts-type\">Continuous welds instead of stitch or intermittent welds<\/td><td class=\"ts-safe\">A continuous weld removes the open ended channel between the plates that a stitch weld leaves behind<\/td><td>Fabricated jackets and water manifolds<\/td><\/tr>\n<tr><td class=\"ts-type\">Drain and dry the circuit during storage and shutdown<\/td><td class=\"ts-safe\">A dry surface breaks the electrolyte path, and flow through the crevice is itself reported to inhibit initiation<\/td><td>Mold storage and long idle periods<\/td><\/tr>\n<tr><td class=\"ts-type\">Avoid pooling on external surfaces and around fittings<\/td><td class=\"ts-safe\">The external surface has to stay cathodic for the crevice to be driven hard, and a wetted external surface supplies that<\/td><td>External layout and insulation<\/td><\/tr>\n<tr><td class=\"ts-type\">Select the seal for the temperature, not for the shop standard<\/td><td class=\"ts-safe\">Temperature is the clearest accelerant, so a seal that hardens and loses contact at the service temperature opens the crevice it was meant to close<\/td><td>O rings, gaskets and face seals<\/td><\/tr>\n<tr><td class=\"ts-type\">Keep stainless and carbon steel in a couple from being the worst pairing<\/td><td class=\"ts-safe\">Galvanic coupling to a more noble material is one of the two ways the potential is raised<\/td><td>Mixed metal assemblies and fittings<\/td><\/tr>\n<tr><td class=\"ts-type\">Clean the deposit, not just the cavity<\/td><td class=\"ts-safe\">A deposit is a crevice former in its own right, and polymer or rust layers shield the metal underneath from oxygen<\/td><td>Maintenance and mould change over<\/td><\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<p class=\"ts-tcap\"><em>Design and operating measures for crevice corrosion, following the order the source uses in its designing to minimize corrosion article. Removing the geometry comes before changing the alloy.<\/em><\/p>\n<p class=\"ts-p\">Two of those measures carry a caveat from the source itself, and both point the same way. Convection is normally ignored in crevice corrosion because the geometry restricts it, so a slow trickle through a channel does not necessarily refresh the gap the way it refreshes the bore. And flow through a crevice is reported to inhibit initiation, but only where the flow actually passes through the gap rather than past its mouth. A cooling channel that is drained and refilled between shifts does more for the crevice than one that is merely kept full. The grade selection that sits behind all of this is on <a href=\"https:\/\/aobosteel.com\/plastic-mold-steels\/\">plastic mold steels<\/a> and <a href=\"https:\/\/aobosteel.com\/mold-steel-property-ranking-chart\/\">the mold steel property ranking chart<\/a>, the stainless options are on <a href=\"https:\/\/aobosteel.com\/martensitic-stainless-steel-properties-chart\/\">the martensitic stainless properties chart<\/a> and <a href=\"https:\/\/aobosteel.com\/4cr13-stainless-steel\/\">4Cr13 stainless steel<\/a>, the cross reference between imported mold steel brands is on <a href=\"https:\/\/aobosteel.com\/imported-mold-steel-brand-cross-reference\/\">the imported mold steel cross reference<\/a>, and the machining and finishing side is on <a href=\"https:\/\/aobosteel.com\/mold-steel-processing-data\/\">mold steel processing data<\/a>.<\/p>\n\n<div class=\"ts-disclaimer\">\n<h3>Before you act on a crevice corrosion diagnosis<\/h3>\n<p>A reference page, it is not an Aobo Steel specification, and the gap range, rates and temperatures above are the values published for the specific alloys, environments and test arrangements named. A crevice prepared in a laboratory is an idealisation, and the gap in a real bolted or threaded joint varies along its length in a way no nominal figure captures. Critical temperatures and repassivation potentials are properties of the specific surface condition and solution that were tested, not of the grade name. Confirm the geometry before replacing a steel, because the most effective measure in every case is removing the gap rather than changing the material.<\/p>\n<\/div>\n\n<p class=\"ts-source\">Source: ASM Handbook, Volume 13A, Corrosion: Fundamentals, Testing, and Protection, ASM International, 2003.<\/p>\n\n<\/div><\/div><\/section>\n","protected":false},"excerpt":{"rendered":"<p>Mold Steel | Corrosion | Water Channels Crevice Corrosion in Mold and Die Steel Crevice corrosion is the attack that happens in a gap too tight to see into and too open to keep dry. On a mold it shows up as a ring of pits under an O ring, a line of attack along [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_uag_custom_page_level_css":"","site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"disabled","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"class_list":["post-21195","page","type-page","status-publish","hentry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v28.6 (Yoast SEO v28.6) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Crevice Corrosion in Mold and Die Steel<\/title>\n<meta name=\"description\" content=\"A gap between 0.1 and 100 micrometres holds the electrolyte an open surface loses. 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