Electrolytic corrosion
Many people may have experienced water electrolyzation in science experiments during the school days. When a platinum electrode is placed in water with electrolyte and electricity is applied, oxygen is generated from the anode and hydrogen is generated from the cathode. A similar phenomenon occurs inside the resistor.
If a resistor is used with moisture or fluid penetrated inside the coating, the resistive film turns into ion and melt out instead of generating oxygen on the anode side. The resistive film eventually disappears, causing a disconnection. This phenomenon is called electrolytic corrosion because the resistive film seems to be eroded by electricity.
The higher the resistance is, the more electrolytic corrosion is likely to occur. This is because the resistive film with higher resistance has thinner film and narrower pattern, which makes it easy to melt in short time.
Electrolytic corrosion occurs mainly in carbon and metal coatings. To prevent electrolytic corrosion, soldered resistors should be cleaned thoroughly to remove electrolyte components, and resistors should be damp sealed. Possibly, if other required characteristics are to be satisfied, using resistors with metal glaze film, which is hard to ionize, can avoid dealing with the electrolytic corrosion.