Numerical simulation of carbon steel atmospheric corrosion under varying electrolyte-film thickness and corrosion product porosity

Abstract

A finite element model is developed to study dynamics of atmospheric corrosion of carbon steel, focusing on the influence of thin electrolyte film thickness under varying corrosion product porosity. Calculations have been done to evaluate the impact of electrolyte film thickness and corrosion product porosity on oxygen diffusion path, and the hindrance effect of corrosion products on the metal surface activity. The time evolution of corrosion current density and controlling steps in the corrosion process are explored. When the corrosion products are loose, oxygen diffusion is the dominant controlling step, and the thicker the electrolyte film, the lower the corrosion rate. When they are dense, the corrosion process is controlled by the mixture of oxygen diffusion and the surface discharge. The oxygen diffusion path is determined only by the corrosion product porosity, and therefore the corrosion rate is not affected by the electrolyte film thickness.

Perspectives on Corrosion Studies Using Scanning Electrochemical Cell Microscopy: Challenges and Opportunities

“…The obtained electrochemical properties of specific microstructures, such as the polarization curve of inclusions, can be employed as more accurate (the inclusions constitute all or most of the probed area) input conditions for finite element method (FEM) simulations of microgalvanic effect studies. 145,146 It is also an efficient way to verify the ab initio model based on density functional theory to evaluate the anisotropic anodic dissolution behavior (calculated polarization curves) of metals and alloys. 16,147 Furthermore, using SECCM is capable of performing high-throughput characterization on some samples (e.g., combinatorial materials chips 148−150 and diffusion multiples 151 ) to efficiently obtain microelectrochemical big data for establishing a database concerning composition−structure−property relationships.…”

“…For instance, the fusion line region in a dissimilar metal welded joint and specific microstructures of high entropy alloys, − can be profoundly investigated using this technique. The obtained electrochemical properties of specific microstructures, such as the polarization curve of inclusions, can be employed as more accurate (the inclusions constitute all or most of the probed area) input conditions for finite element method (FEM) simulations of microgalvanic effect studies. , It is also an efficient way to verify the ab initio model based on density functional theory to evaluate the anisotropic anodic dissolution behavior (calculated polarization curves) of metals and alloys. , Furthermore, using SECCM is capable of performing high-throughput characterization on some samples (e.g., combinatorial materials chips − and diffusion multiples) to efficiently obtain microelectrochemical big data for establishing a database concerning composition–structure–property relationships. Using data-driven methods, a predictive mathematical model (i.e., a mathematical model of the composition–structure–property relationships) can be constructed to facilitate the screening of new alloys.…”

Physics-Informed, Data-Driven Model for Atmospheric Corrosion of Carbon Steel Using Bayesian Network

“…However, because of the limited availability of data for the parameter estimation and the high level of uncertainty in predicting results, a practical application of the corrosion deterioration model is difficult [9][10][11]. Previous studies have modeled multiple physical phenomena related to atmospheric corrosion using commercial software such as COMSOL Multiphysics (4.2 and 5.6) [12][13][14][15][16][17]. The previous models included several assumptions and had limitations in representing the corrosion environment of specific regions, because the modeling results were verified by conditions created in a laboratory.…”