The paper describes the corrosion based degradation of aluminium alloys using an analytical and numerical framework. The corrosion rate was calculated using analytical equations for aluminium sheets subjected to a corrodent. Parametric analysis for the pit morphology, diameter, depth and distribution on the plate was conducted using finite element analysis. A comparison between elliptical and circular pits of the same area was also made for stress magnification using numerical analysis. It was observed that the stress generated at constant load when a specimen corrodes due to pitting is directly proportional to the pit diameter and pit depth. Zigzag pit morphologies due to the combined effect of mechanical degradation and corrosion have the highest stress at the corners of the pattern, while circular pits have the highest stress at the centre of the pit. The zigzag pit morphology has more detrimental effects than circular pits. For multiple distributed pits, the pits closer to the specimen edges exhibit higher stress values than those near the centre of the specimen. The effect of multiple or quantitatively increased number of pits having smaller geometric properties has a more detrimental effect than a single pit with larger geometric attributes.
The effect of specimen width and incorporation of a circular hole on the tensile behaviour of commercially available aluminium alloy AA 1100 was studied using finite element analysis (FEA) for convergence with the already published experimental work of other researchers. Static structural analysis was conducted to simulate tensile loading of Japanese industrial standard (JIS) specimen JIS Z 2201 No. 13B and No. 5 until the point of the ultimate tensile strength (UTS) was reached. A strain rate of 0.25 mm/s was used for both the neat specimen and the one bearing a circular hole of 8 mm in diameter at the centre of the specimen. The numerical results exhibited a good agreement with the experimental work by comparison of the percentage elongation for numerical and experimental data. The normal stresses calculated using analytical and numerical approaches also reflected a good convergence. For neat specimens of JIS Z 2201 No. 13B and No. 5, a 100 % increase in specimen width enhanced the load required to reach UTS by 100 %, while elongation was increased by 30 %. On the other hand, for specimens of JIS Z 2201 No. 13B and No. 5, bearing an 8 mm circular hole reduced the load required to reach UTS by 300 %, while elongation was only increased by 25 %. The 200 % decrease in load required to reach UTS and 57 % reduction in elongation was observed by incorporating an 8 mm circular hole in the neat specimens.
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