Industrial Strategies to Control Corrosion in Aerosol Cans

2. Internal Coatings (Lacquer Systems)

The coating must resist:

• Surfactant wetting

• pH drift

• Water permeability

Common successful systems:

• Epoxy-phenolic hybrid lacquers

• Acrylic-epoxy copolymers

• Polyester-based lacquer systems for high-pH cleaners

Use of Corrosion Inhibitors

Corrosion inhibitor packages are designed to reduce or block metal–water interaction at the can surface. Effective inhibition typically involves a combination of mechanisms, including:

• Surface Passivation: Formation of a thin, adherent protective film on the metal surface to prevent direct contact with water and dissolved ions.

• Boundary Layer Modification: Reduction of solution wetting and surface spreading, so the formulation does not maintain continuous contact with the can wall.

• Ion Activity Control: Stabilization or neutralization of reactive ions that can trigger or accelerate corrosive attack.

• pH Stabilization: Keeping the formulation within a non-aggressive pH window over shelf life, even under temperature fluctuations or additive breakdown.

• Headspace Protection: Establishing a vapor-phase barrier that protects not only the liquid-contact area but also the internal surfaces exposed to the pressurized gas phase.

• Localized Defect Protection: Inhibitors migrate preferentially to scratches, seams, and coating discontinuities, where corrosion would initiate first.

Facing Corrosion Challenges in Water-Based Aerosols?

If you're experiencing shelf-life failures, product instability, or can corrosion issues, we can help.
Global Aerosols provides end-to-end support including formulation optimization, corrosion-inhibitor strategy, packaging compatibility selection, and accelerated testing protocols.