Metal Corrosion Rate Calculator

Calculate average metal corrosion rate from weight loss, exposed surface area, material density and exposure time. Results are provided in mm/year, µm/year, mils/year and inches/year.

Weight loss & exposure

kg/L

Calculation method

Weight loss
Weight loss is the mass removed from the specimen during the exposure period.
Corroded volume
Lost volume = weight loss ÷ material density.
Equivalent thickness loss
Thickness loss = lost volume ÷ exposed surface area.
Corrosion rate
Corrosion rate = equivalent thickness loss ÷ exposure time.
The result is an average equivalent penetration rate based on total mass loss. It does not directly measure localized pit depth.

Common corrosion rate units

Primary result
mm/year
Micrometres
µm/year
Imperial
mils/year
Imperial thickness
in/year
For standardized laboratory reporting, use the specimen area, cleaning procedure, density and reporting conventions required by the applicable corrosion-testing standard.

Understanding weight-loss corrosion testing

If both sides and edges of a coupon are exposed, include those surfaces in the exposed-area value. Do not automatically use only the largest face.

Example calculation

2.5 g weight loss
A specimen loses 2.5 g during the exposure period.
100 cm² exposed area and 7.85 kg/L steel density
The weight loss corresponds to an equivalent average thickness loss of approximately 3.185 µm.
720 hours exposure
The estimated average corrosion rate is approximately 0.0387 mm/year, or 38.7 µm/year.

Frequently Asked Questions

How do I calculate corrosion rate from weight loss? Convert weight loss into lost volume using density, divide by exposed surface area to obtain equivalent thickness loss, then normalize it to one year.

Why do I need surface area? The same mass loss represents different corrosion rates depending on whether it occurred over a small or large exposed surface.

Why is density required? Density converts the measured mass loss into an equivalent volume of metal removed.

Can I enter initial and final specimen weight? Yes. Switch the mass measurement option and the calculator will determine the weight loss automatically.

Can this calculate steel corrosion rate? Yes. Select the steel preset or enter the density appropriate for your specific material.

What is the difference between mm/year and mils/year? They are different thickness-rate units. One mil equals 0.001 inch, while 1 mm equals approximately 39.37 mils.

Does weight loss detect pitting? Weight loss provides an average corrosion penetration rate. A component can have severe localized pitting even when its average weight-loss rate is relatively low.

Can I use this for field corrosion inspection? It can help estimate average corrosion from coupon or mass-loss data. Actual field thickness loss should be assessed using appropriate inspection measurements and engineering procedures.