If you think there is a chance your gun will be exposed to sweat get the 642. I previously had a 642 that I replaced with a 442 because I prefered the black finish. I now wipe surface rust off the barrel and cylinder of the 442 everyday I carry it. I never had any problems with rust on the 642. I did have problems with the clear coat flaking off near the top of the grip, but no rust. So, if anyone has a nice 642 they want to swap for a 442 let me know.
I've carried a 442 for years (actually more than one) in all conditions - the worst being dunked when I turned a kayak over. I have never had any rust on mine. I have about 1500 rounds thru that one and it still looks good. I do wipe down whatever I carry about once a week, or more frequently if I've sweated bad that day. I think maybe you just got one from a bad batch. The Airweights are about the last gun in my safe I enjoy shooting (not my favorite handgun) but they sure carry well.