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Thanks again for the thoughts
Having just seen a picture of a charred out plug from an iron left on overnight, I suspect it is simply burning out. It’s set to 70*c (don’t ask) and although on a morning /afternoon timer, it’s probably just burning brightly for its short life… Not sure I have the inclination to fit a new tank with two elements, but just have some themostats on hand each winter I guess.
Chopsicle
Airhead
It does sound like 'normal' failure patterns for a thermostat immersed in water but seems like the intervals are a bit short. On the other hand most electric immersions that I come across these days are only a backup for a gas heating option so they're not heat cycling that regularly.
I wouldn't expect rust after 12-18 months. Could be internal failure not related to water but some sort of water ingress is also likely given it's immersed in a tank.
I'm scratching my head to think of some way the wiring could be a cause but can't come up with one.