Is Car Battery Corrosion Dangerous? Safety Tips

Car Battery Corrosion: What Causes It and How To Deal With It Safely

Car battery corrosion and battery acid can pose serious safety hazards, not only to vehicle components but also to people handling or exposed to these substances. Corrosion on battery terminals and leaks of battery acid are common issues in automotive batteries. This article discuss whether car battery corrosion is dangerous, how the corrosion and battery acid interacts with automotive components, the health risks they pose, and precautions for safe handling and maintenance.

What Causes Battery Corrosion?

Battery corrosion generally appears as a white, blue, or greenish substance around the battery terminals. It results from a chemical reaction between the sulfuric acid in the battery and the surrounding environment, which includes oxygen and humidity. Over time, this can cause a buildup that impedes the battery’s electrical connections and can eventually damage terminals, cables, and connectors.

Battery acid is sulfuric acid diluted with water. Sulfuric acid is a highly corrosive chemical that can cause burns, respiratory issues, and severe damage to various materials, including plastics, metal, and skin. In vehicles, any leakage of battery acid is especially dangerous because it can eat away at nearby metal components, damage wiring, and lead to costly repairs.

What exactly causes the corrosion

Corrosion is a problem that occurs with lead-acid batteries

Notice the corrosion and the wetness on the top of the battery. This car battery is leaking between the case and the post

when the volatile chemicals or gases inside a battery escape and come into contact with the highly-conductive metal of the battery terminal. The batteries can release gases filled with hydrogen, sulfur, and acids that damage nearby battery terminals if not vented properly. Source: Battlebornbatteries.com

1) Overheating— Batteries that are overcharged or overheat due to higher temperatures are more likely to develop corrosion. That’s why corrosion risk is highest in the summer.

2) Leaking fluid— Over time the seal between the battery case and the battery posts can allow sulfuric gasses to escape and react with moisture in the air and the copper in the battery terminals. That forms a blue powder due to copper sulfate. However, car batteries can also crack around the battery hold-down brackets if they’re over tightened. If your battery is cracked or damaged, battery acid can leak from the casing and cause corrosion around the battery terminals.

3) Constant Undercharging— Corrosion that appears on the negative battery terminal is a symptom of undercharging. This can happen if you’re taking short drives and your electronic system is drawing a significant amount of battery power for onboard electronics.

4) Overcharging— If you notice corrosion on your battery’s positive terminal, it’s a sign that your battery may be overcharging, which can be due to a faulty voltage regulator.

Why Battery Corrosion and Battery Acid Are Dangerous

Battery corrosion is dangerous to your health

Skin and Eye Irritation — Sulfuric acid from a leaking battery can cause serious burns to the skin and damage to the eyes. Even touching corroded material on the battery terminals can lead to skin irritation or burns because of the acidic residue. Using protective gear, such as gloves and safety goggles, is crucial to prevent direct exposure.

Respiratory Issues — Battery corrosion produces hydrogen gas, an odorless and potentially explosive substance, especially in confined areas. Inhaling high concentrations of hydrogen can cause respiratory difficulties. Additionally, inhaling vapors from battery acid can irritate the throat and lungs, posing an increased risk for individuals with respiratory conditions.

Poisoning Risks — Battery acid is highly toxic if ingested, even in very small quantities. While accidental ingestion is rare, there’s a risk to young children and pets, particularly if acid leaks from the battery stored outside of its protective compartment.

Is Battery Corrosion Dangerous to Vehicle Components

Electrical Impairment — Corrosion around battery terminals increases resistance in the electrical circuit, reducing the battery’s ability to supply power effectively. This can result in electrical malfunctions, starting issues, or even sudden power loss.

Metal Degradation — Battery acid is highly corrosive to metals like steel, aluminum, and iron. If it leaks, it can corrode nearby metal parts, potentially causing structural damage or failure of critical components, including the battery tray, bolts, alternators, and wiring harnesses.

Increased Repair Costs — Ignoring battery corrosion or acid leaks can lead to escalating repair costs. Replacing damaged wiring, corroded connectors, or other affected components can be expensive, and unchecked corrosion may ultimately result in full battery failure, necessitating an earlier-than-expected replacement.

Preventive Measures and Safe Handling Practices

1. Wearing Protective Gear

When working with or inspecting a battery, wearing gloves, safety goggles, and long sleeves can help protect against accidental exposure to acid. Gloves and goggles should be made from materials resistant to sulfuric acid, like nitrile or neoprene.

2. Avoiding Sparks and Flames

Battery acid and corrosion around battery terminals can release hydrogen gas, which is highly flammable. Working with the battery in a well-ventilated area and avoiding any source of sparks or flames is essential to minimize the risk of explosion.

3. Using Proper Cleaning Methods

To clean corrosion from battery terminals safely, use a solution of baking soda and water, which neutralizes the acid. Apply the solution with a toothbrush or small brush to gently scrub the corrosion. Avoid using metal tools, as they can cause sparking if they come into contact with the terminals.

What to Do if Exposed to Battery Acid or Corrosion

If you come into contact with battery acid or corrosion, it’s critical to act quickly:

• Skin Contact: Rinse the affected area with water for at least 15 minutes to dilute and remove the acid. Then, wash the area with mild soap, and if irritation continues, consult a medical professional.
• Eye Contact: Exposure to battery acid in the eyes is particularly dangerous and can result in permanent vision loss. Immediately flush the eyes with lukewarm water for at least 15 minutes, and seek medical attention without delay.
• Inhalation: Move to an area with fresh air and avoid further exposure to fumes. If you develop symptoms like coughing or trouble breathing, contact a healthcare provider.
• Ingestion: If battery acid is ingested, seek emergency medical assistance right away. Do not induce vomiting, as this may cause additional internal damage.

Environmental Hazards and Disposal

Battery acid is hazardous to the environment. Improperly disposing of batteries or pouring battery acid down drains can lead to contamination of soil and water supplies. It’s essential to dispose of batteries at designated recycling centers to ensure that any acid and lead are safely handled and recycled.