Crevice Critical Gap Size (CCGS)

The key parameter of crevice corrosion is the critical crevice gap size (or critical interstice size),
defined as the minimum that allows the aggressive environment to enter the interstice but impedes the
diffusion of oxygen. Critical gap size is between 0.1 µm and 0.1 mm, depending on metal composition.
From literature data, in particular from Oldfield and Sutton (1978), the critical crevice gap size for
stainless steels, assuming a crevice depth of 5 mm, can be estimated by the following equation:

where CCGS is in μm and PREN is pitting resistance equivalent number, which is calculated from
stainless steel composition (see Chap. 11). Crevice corrosion occurs when gap size is smaller than the
critical one. In general, the narrower and deeper the gap the higher the risk of crevice occurrence.

Figure below illustrates typical conditions that give rise to crevice corrosion as follows:

 Cracks in the metal, typically due to lack of penetration in welds

 Surface overlapping as in joints and threaded connections. If metals are different, galvanic
effects have to be evaluated
 Interstices between metal and non-metallic materials (plastic, rubber, glass or wood) as typically
in flanges and sealing gaskets
 Presence of deposits or scales or corrosion products or fouling.

For example, in a heat exchanger, critical situations are: interstices between plates, tubesheet
and tube, tube and diaphragm, welding defects, supports, spacers, joints (bolted or riveted or forced),
under gas bubbles (gas-liquid-metal three-phase contact), under deposits and porous coatings.

Severe crevice occurs in conditions of high heat flux as, for example, in gaps that form between
tubes and tubesheet in boilers; this situation worsens by the formation of deposits and the increase in
concentration of aggressive species.

Figures below show examples of crevice corrosion of stainless steel in seawater.

Fig. Crevice corrosion on AISI 321 stainless steel after a few months in seawater

Fig. Crevice corrosion on AISI 316 stainless steel in seawater