Corrosion Model Research Articles

Study on mechanical properties of locally corroded square steel tube short column

To investigate the axial compressive properties and failure modes of 18 locally corroded square steel tube short columns, salt spray corrosion tests were conducted. The findings indicate that local corrosion in the horizontal direction significantly impacts the ultimate bearing capacity of the specimens, with all failures occurring in the corroded areas. However, the influence of the corrosion area on the ultimate bearing capacity and ductility of the specimens is not evident. A local corrosion model for square steel tube short columns was developed using the finite element method. The ultimate bearing capacity determined through finite element simulation closely aligns with experimental results, validating the reliability of the simulation approach. Moreover, a comparison is made between the prediction models of the BP neural network and the GA-BP neural network, with the prediction effectiveness of each model evaluated using the leave-one-out method. The verification results indicate that the GA-BP neural network model demonstrates superior predictive performance, with an average error of 3.14%.

The beginning of iron corrosion - high-resolution visualization with 3D electron tomography

Understanding the genesis and early-phase reactions of iron corrosion is essential for the early detection, mitigation and prevention of metal degradation. In this work, high-resolution 3D tomography of metallic iron oxidation was acquired using high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM). In particular, dendritic capillaries (<0.5 nm) were observed during the initial oxidation of fresh nanoscale zero-valent iron due to the differential oxygen diffusion and iron atoms migration. This observation led to the proposal of a nanoscale “pothole” model for early-phase corrosion, wherein hollowing out of the metal nanoparticle and formation of nanovoids beneath the iron/oxide interface through Kirkendall effect. Coalescence of the nanocapillaries results in the ultimate collapse of metal structure and/or functional failure. Using nanoscale zero-valent iron as a research model, this work provides unprecedented insights into the nano- and atomic-scale mechanisms of iron oxidation, paving the way for advanced detection and prevention strategies for iron corrosion.

The role of climate change and corrosion modeling strategy in dynamic response of pile-supported wharves

This paper explores the fragility of pile-supported wharves to environmental hazards, notably climate change and corrosion, and underscores the critical need to understand the interplay between these factors when assessing structural safety. The research advocates for comprehensive methodologies that encompass climate change effects, aging, and time-dependent deterioration in evaluating the seismic fragility functions of pile-supported wharves. An examination of aging and seismic effects is performed on a representative pile-supported wharf at designated time intervals. This study highlights the pronounced impacts of climate change and corrosion on the structural integrity of concrete and steel in marine environments. Specifically, it considers effects such as sea level rise, increased temperatures, and heightened relative humidity on pile-supported wharves. Additionally, three corrosion pitting configurations in prestressed strands with and without climate change considerations are analyzed to determine their influence on the strength and ductility of materials, limit states, and ultimately, on the fragility curves. The findings indicate that climate change significantly exacerbates the corrosion of materials in pile-supported wharves, and increases failure probability. The relative increase in corrosion rate after 50 years due to climate change is found to be 94%.

Subset simulation based simplified approach for pipeline with multiple irregular corrosion defects in time-dependent reliability analysis

Pipeline system plays an important role in the natural gas and petroleum transportation, and it is widely employed in the engineering application. However, the pipeline system is subjected to corrosion given the industry environment condition, or soil condition when it is buried. In this case, it is important to assess the remaining life of corroded pipeline. Consequently, it is important to predict the failure probability considering the corrosion growth over time and operating pressure. Nevertheless, the prediction of failure probability in corroded pipeline in not an easy task, due to the fact that a realistic corrosion usually has an irregular geometry, especially, when multiple irregular corrosion is involved in the analysis. To simplify the problem, this work presents a simplified procedure for time-dependent reliability analysis to predict the failure probability in pipeline with multiple irregular corrosion defects, considering two failure modes, the burst and leak mode. The approach is based on Subset Simulation and Weighted Depth Difference method, where the multiple irregular corrosion is treated by a discretization procedure and a weighting coefficient is evaluated in every discretization points. Then, this weighting coefficient is introduced into burst pressure assessment, which is employed by burst failure mode limit state function. In this work, the corrosion growth is modelled by power function corrosion model, and initial corrosion depth is generated randomly. The Subset Simulation is employed to evaluate the failure probability, where the Markov Chain Monte Carlo is adopted to evaluate the conditional probability and Metropolis-Hasting algorithm is employed to solve the problem. Finally, several scenarios with single and multiple irregular corrosion defects are analyzed to demonstrate the effectiveness of presented procedure.

Morphogenic Modeling of Corrosion Reveals Complex Effects of Intermetallic Particles.

Corrosion processes are often discussed as stochastic events. Here, it is shown that some of these seemingly random processes are not driven by nanoscopic fluctuations but rather by the spatial distribution of micrometer-scale heterogeneities that trigger fast reactions associated with corrosion. Using a novel excitable reaction-diffusion model, corrosion waves traveling over the metal surface and the associated material loss are described. This resulting nonuniform corrosion penetration, seen as a height loss in modeling, exposes buried intermetallic particles, which depending on the local electrochemical state of the surface trigger or block new waves. Informed by quantitative experimental data for the Mg-Al-Zn alloy AZ31B, wave speeds, wave widths, and average material loss are accurately captured. Morphogenic mitigation based on wave-breaking microparticles is also simulated. While AZ31B corrosion is identified as a process driven by rare-wave events, this study predicts several other corrosion regimes that proceed via spots or patchy patterns, opening the door for new protection, design, and prediction strategies.

The history and the current state of the art related to structures under stress and corrosion

The paper deals with the current state of the art arising in the design of the structures, operating under traditional mechanical loading in the aggressive environment causing their corrosion. The express goal in this case is establishing the corrosion rate dependence on the stress state of the structure and considering its durability. Thus, the use of basic mathematical models that describe the effect of corrosion rate depending on the stress state of the structure is considered. The main objective of this paper is to provide a review of useful approximations that have been suggested to deal with interaction of stress and corrosion fields. The first model that considers such a relationship is the Dolinsky model, which uses a linear dependence of the stress effect on the corrosion rate. Additionally, the Gutman model, in which the dependence of the corrosion rate on stress is expressed by an exponential law, is considered. When constructing mathematical models of structures’ corrosion wear, it is also necessary to take into account the protective coatings operation and determine the incubation period duration, which is the durability of the applied protective coatings. In this regard, the use of one of these models, which takes into account the decrease in the polymer coatings’ protective properties and a combined approach to accounting for corrosion and the anti-corrosion coatings’ protective properties are presented. Determining their reliability is an equally important aspect in the design of structures subject to corrosion. Therefore, the main theories of reliability and their practical application were considered on specific examples. A characteristic feature of the work is the coverage of issues related to the optimal design of structures operating in corrosion conditions. Two classes of problems were studied. First, determining the optimal form of structures under various types of mechanical loading and the use of the above corrosion models is considered. In the second class, the use of promising optimization models related to the solution of multi-criteria problems (using the fuzzy sets theory), as well as models with a pronounced economic bias, which allow making a cost estimate of structures failure-free operation during their lifetime, is considered. This article's novelty consists of preparing a comprehensive review of the interaction of stress and corrosion conditions. Researchers are deemed to greatly benefit from knowing the existing literature along with their strengths and weaknesses.

Optimization and Evaluation of Accelerated Corrosion Tests Based on Mechanism Equivalence Principles.

Conventional indoor corrosion test design methods primarily focus on the rapid evaluation of material corrosion resistance, often neglecting the impact of environmental stress levels on the equivalence of corrosion mechanisms. This study introduces a novel indoor corrosion test design method based on the principle of corrosion mechanism equivalence, aimed at improving the accuracy of indoor accelerated corrosion simulations. We define the characteristic of corrosion mechanism equivalence as the Corrosion Mechanism Equivalence Degree (CMed), which quantifies the similarity between corrosion mechanisms in indoor accelerated tests and field tests. Then, modified conventional link function models are defined, integrating the probability distribution of environmental factors to estimate corrosion model parameters more precisely. Finally, an optimization problem is constructed for accelerated corrosion tests based on CMed, incorporating constraints on environmental stress levels and acceleration factors. A case study demonstrates the proposed method's ability to accurately simulate the actual service environment of materials, determining the appropriate stress levels for indoor accelerated corrosion tests while ensuring the desired acceleration factor and corrosion mechanism equivalence.

A Multiscale Inelastic Internal State Variable Corrosion Model.

We present a corrosion internal state variable (ISV) damage model based upon the integrated computational materials engineering (ICME) hierarchical multiscale paradigm. Structure-property experiments for magnesium alloys were used where the only inputs were the volume fractions of each element of the periodic table. This macroscale ISV corrosion model finds its basis in Horstemeyer's mechanical damage model, which includes three separate ISVs for damage nucleation, growth, and coalescence, as well as Walton's inclusion of corrosion, which introduces five new ISVs for pit nucleation, growth, and coalescence, along with general corrosion and intergranular corrosion. While Walton's corrosion ISVs are phenomenological in nature, herein we develop a multiscale physical basis for the corrosion ISVs. The parameters for the macroscale corrosion ISVs were garnered from the mesoscale Butler-Volmer equations. Pure magnesium with differing amounts of aluminum were used in corrosion tests to exemplify the different pitting, general corrosion, and intergranular corrosion rates, and the macroscale ISV model was calibrated with said data, in which the only inputs to the model are the volume percentages of the elements magnesium and aluminum. Although magnesium alloys were used to motivate and calibrate the model, the model is abstract enough to possibly capture other material systems as well.

An Electrochemical Phase Field Model Applied to Molten Salt Dealloying Corrosion of Ni-Alloys

Metal alloys in contact with molten salts are known to corrode via a dealloying process, wherein the less-noble alloy elements (e.g. Cr) are selectively oxidized and dissolved, leaving behind a corroded structure that is enriched in the more-noble elements (e.g. Ni). In some cases, this can lead to molten salt infiltration into the alloy through discrete channels along specific microstructural features (e.g. grain boundaries). However, in other cases the dealloying process promotes a more full-scale attack of the alloy, generating a fine-scale ligament structure. This process can severely degrade the alloy’s structural integrity, which limits the practicality of these material systems in otherwise promising applications (e.g. molten salt-cooled power reactors).The thermokinetic conditions for dealloying corrosion depend on the salt chemistry and the metal microstructure, which together inform the reaction process occurring at their interface. The salt chemistry and oxidant content set the electrochemical potential for selective oxidation of the less-noble elements. The associated oxidation rate is expected to depend on the presence of an interfacial structure (e.g. double layer) and also on the transport rates of reactants towards the interface (e.g. species diffusion in the metal and oxidizer transport in the salt) and reaction products away from the interface (cation transport in the salt). The corrosion rate and morphology will also depend strongly on the rate of transport laterally along the metal-salt interface, since the reorganization of the more-noble species (Ni) towards ligament formation facilitates the attack of the alloy by the corrosive agent. It has been hypothesized that molten salts enhance this rate of solute diffusion along the metal interface.In this work, we propose an electrochemical phase field model to predict the microstructural evolution of model Ni-alloys undergoing dealloying corrosion in molten fluoride salts. The model incorporates metal oxidation and dissolution via experimentally determined redox potentials and activity coefficients for metal species in the molten salt. We show that the corrosion rate and development of pores is strongly dependent on solute transport rates within the metal and also along their solid-liquid interface. In particular, we reveal a mechanism in which grain boundaries couple with the solid-liquid corrosion front to promote rapid dealloying and molten salt attack. Oxidant content in the salt and double-layer formation at the interface are discussed for their roles in setting the electrochemical potential and reaction rate at the metal-salt interface. Finally, we discuss how the model leverages insights from atomistic modeling and highlight key knowledge gaps in the mesoscale modeling of electrochemical molten salt corrosion.

Rate effect of rocks: Insights from DEM modeling

Rocks are subjected to different loading rates at different construction stages and engineering applications. The strength of rock usually increases with loading rate. This rate dependency is one of the time-dependent behaviors of rock, whereby the micro-mechanisms are believed to be the subcritical crack growth due to stress corrosions. However, no evidence is provided yet. This study investigated rate effects of rocks through a novel implementation of Parallel-Bonded Stress Corrosion (PSC) model in Discrete Element Method (DEM). Long-term microparameters in PSC are first calibrated through creep test. Then, a series of uniaxial compressive strength, direct tensile strength, and triaxial compressive strength tests are performed, with strain rates ranging from 1×10−7/s to 1×10−3/s. Results show that the uniaxial compressive strength is highly dependent on strain rates which quantitatively matches with the experimental data. At lower strain rate, more subcritical cracks propagate due to longer stress-corrosion reaction time, resulting in a lower strength. Besides, strain rate also influences the failure patterns in post-peak, with single failure plane at lower strain rates and multiple failure planes at higher strain rates. Rate effects are also observed in direct tensile strength tests, with similar rate of increase in strength and a transition in cracking pattern, which align with the experimental data, indicating tension-induced subcritical cracking is the unified underlying micro-mechanism of rate effects for both cases. However, in triaxial compressive strength tests, rate effects become less obvious with increasing confining pressure, consistent with experimental findings, as subcritical crack growth is suppressed in shearing processes.

Oxic corrosion model for KAERI Reference disposal system via O2 consumption reactions and mixed-potential theory

The durability of copper (Cu) canisters against corrosion is critical for the licensing of deep geological repositories. Assessing oxic corrosion, a primary degradation mechanism, is essential for ensuring the reliability of such repositories. Due to the complex interactions influencing oxic corrosion, a comprehensive model is necessary for evaluating Cu canister corrosion. This study develops a model for the KAERI Reference Disposal System (KRS), incorporating mixed-potential theory with key O2 consumption reactions, including Cu corrosion, Cu(I) oxidation, FeS2 oxidation, aerobic microbial activity, and O2 dissolution and consumption. Simulation of 11 scenarios revealed that the representative KRS case would experience a maximum corrosion depth of 9.3 μm on the Cu canister after 2.3 years due to oxic corrosion, under conditions that are unfavorable for the initiation of pitting corrosion. These results suggest that oxic corrosion is not a threat to the isolation of spent nuclear fuels in KRS.

Corrosion mechanism of postmortem converters slag-blocking ZrO2 sliding gate

The post-service ZrO2 sliding gate for converter slag-retaining was examined by XRD, SEM, EDS and X-CT to investigate its corrosion mechanism. The results show that m-ZrO2 in the hot working layer transform into stable t-ZrO2, and cracks and flaws are generated due to the accompanied volume contraction, leading to severe slag penetration. The CaO in the slag preferentially reacts with ZrO2, forming a CaZrO3 dense layer with a high melting point to prevent slag penetration. While SiO2-Al2O3-FeO component in the slag removes the MgO stabilizer out of Mg-PSZ crystals, causing destabilization and decomposition of the Mg-PSZ grains. The microstructure loses its integrity and is easily spalled. A corrosion model was established.

Evaluation of the optimal Y content for the FeCrAl coating with excellent LBE corrosion resistance

FeCrAlY coating with excellent LBE corrosion resistance is considered one of the most important candidate corrosion-resistant coatings in LFRs. However, the critical Y content required to obtain excellent comprehensive properties and the influence of varying Y content on corrosion resistance is still unknown. In this study, FeCrAl coatings with Y content from 0.5 - 5 wt.% were corroded at 500 - 600 °C for 1000 h in static LBE. All the coatings can provide efficient protection for the substrate from LBE corrosion. The FeCrAl0.5Y coating has the best corrosion resistance (with an oxide scale thickness of only ∼ 61 nm), and the increased Y content leads to deteriorated performance. A three-layered corrosion layer formed on the surface of the coatings and the Y element is only distributed in the middle and innermost layers. The corrosion mechanism was discussed and a corrosion model was put forward. The outstanding corrosion resistance of the FeCrAl0.5Y coating makes it possible to have the prospect of practical application in LFRs.

Numerical modeling of non-uniform corrosion of concrete reinforcement considering calcium leaching and chloride diffusion coupling effect

A novel numerical model is proposed for characterizing the nonuniform corrosion of steel bars. The proposed model corrects the anodic Tafel slope through the concentration of chloride and accounts for the adsorption-binding impact of chloride. The viability of the presented model is confirmed with regard to chloride diffusion and the distribution of steel corrosion products. The rebar-concrete interface's non-uniform distribution of oxygen and chloride concentrations along the circumferential direction influences the corrosion current density. Calcium leaching influences the migration of oxygen and chloride, and speeds up the electrochemical corrosion of the rebar.

A microscopic approach to brittle creep and time-dependent fracturing of rocks based on stress corrosion model

A brittle creep and time-dependent fracturing process model of rock is established by incorporating the stress corrosion model into discrete element method to analyze the creep behavior and microcrack evolution in brittle rocks at a micro-scale level. Experimental validation of the model is performed, followed by numerical simulations to investigate the creep properties and microcrack evolution in rocks under single-stage loading, multistage loading, and confining pressure, at various constant stress levels. The results demonstrate that as the stress level increases in single-stage creep simulations, the time-to-failure progressively decreases. The growth of microcracks during uniaxial creep occurs in three stages, with tensile microcracks being predominant and the spatial distribution of microcracks becoming more dispersed at higher stress levels. In multi-stage loading-unloading simulations, microcracks continue to form during the unloading stage, indicating cumulative damage resulting from increased axial stress. Additionally, the creep behaviour of rocks under confining pressure is not solely determined by the magnitude of the confining pressure, but is also influenced by the magnitude of the axial stress. The findings contribute to a better understanding of rock deformation and failure processes under different loading conditions, and they can be valuable for applications in rock mechanics and rock engineering.

Research on the Corrosion Mechanism of Ancient Celadons from the Dalian Island No. 1 Shipwreck

ABSTRACT The micromorphology and composition of three pieces of ancient celadon with various degrees of corrosion salvaged from Dalian Island, Pingtan County of East China's Fujian Province were analyzed. The results indicate that there were black corrosion products with a high content of Fe and Mn and white crystals with high concentrations of Ca and Mg on the surfaces of the samples. The black corrosion products infiltrated into the interior along the cracks on the sample surfaces, producing corrosion products mainly composed of FeOOH and MnO2. Meanwhile, there were white crystals containing MgCa(CO3)2 gathering on the black corrosion surface. Subsequently, the attachment of a biological carbon film containing proteins and polysaccharides in the corrosion area was determined by Fourier transform infrared spectroscopy and steady state and transient fluorescence. It is speculated that the existence of a bio-film and the presence of Fe and Mn oxides is related to the microbial corrosion and mineralization of iron bacteria in the marine environment. In this paper, through the analysis of the corrosion products of the effluent celadons as well as the study of iron bacterial biological corrosion and biomineralization, the corrosion model is explained and established so as to clarify the microbial corrosion mechanism of celadon ceramics retrieved from the seabed.

Effect of Cerium on Inclusion Evolution and Pitting Corrosion of Nb-Microalloyed Steel.

Nb-microalloyed steels are widely used in construction engineering fields due to their excellent mechanical properties, but they face serious corrosion problems in service environments. Pitting corrosion is the severest form of corrosion, and the types of inclusions are the leading cause to induce pitting corrosion. A new strategy is proposed to enhance the corrosion resistance of steels by achieving a beneficial transformation of inclusions with Ce treatment. In this paper, two types of Nb-microalloyed steels (0% Ce and 0.0058% Ce steel) were prepared to study the modification effect on inclusions in industrial production. The spherical CaS•C12A7 inclusions were modified to smaller ellipsoidal Ce2O2S inclusions, and the proportion of inclusions (0-2 μm) increased significantly from 27 to 66%, while large inclusions (>6 μm) disappeared. A kinetic model of inclusion evolution was established. The results of electrochemical tests indicated that the corrosion potential was positively shifted, and the corrosion current was reduced after Ce treatment. Additionally, the number of defects in the passivation film was decreased, and the corrosion resistance of the steel was significantly improved. The addition of Ce changed the types of inclusions and reduced the number of pitting nucleation points, which led to a remarkable reduction in the number and size of pitting pits. The mechanism of pitting corrosion induced by different types of inclusions was further investigated, and a pitting corrosion model was modeled based on the immersion experiments. Research results provide theoretical support for enhancing the corrosion resistance of steel.

Assessing sulfate-reducing bacteria influence on oilfield safety: Hydrogen sulfide emission and pipeline corrosion failure

With the further development of oilfield, excessive sulfate-reducing bacteria (SRB) has intensified odors and increased pipeline leakage incidents. Accurate predictive models of H2S emission and pipeline corrosion based on SRB content are essential for safety. This study analyzed the correlation between sulfide content and SRB content at different nodes in the injection-production system of Daqing Oilfield, and characterized the pipeline corrosion products using scanning electron microscopy (SEM), X-ray diffraction (XRD), and stereo microscope. Corrosion rates were investigated through 18 sets of orthogonal experiments, considering factors such as SRB, temperature, pH, liquid flow rate, CO2 partial pressure, and H2S partial pressure, and the main controlling factors of corrosion were identified. Finally, the risk models for H2S emission and corrosion rate based on SRB content were established under on-site operating conditions. The results show that a significantly positive correlated between SRB and sulfide content at different nodes, with the highest levels observed at the settling tank, indicating the highest risk of H2S emission. SRB contributed to corrosion in both water injection and oil collection pipelines, with more serious corrosion in the water injection pipeline. SRB and pH were identified as the main factors influencing corrosion rate. The H2S emission prediction model based on the correlation of SRB and sulfide was reliable, with an accuracy exceeding 90 % compared to the measured results. Additionally, the corrosion rate model for pipelines, related to SRB content, had an error of less than 7 %. To minimize risks, it is recommended to maintain a low risk environment in the injection-production system by sterilization and increasing the pH of water. This study has significant theoretical importance for ensuring the safe operation of injection-production systems.

A framework to analyse the probability of accidental hull girder failure considering advanced corrosion degradation for risk-based ship design

Ship’s hull girder failure could result from maritime accident that can cause human life loss, environmental disaster, and major economic impacts. In risk-based ship design paradigm, accounting for rare phenomena (e.g. ship-ship collision or grounding) is important to provide safe and durable structure. In-service corrosion-induced hull degradation should be considered at the design stage, as it can significantly affect structural strength. The current study presents a novel framework to estimate the probability of ship hull girder failure, accounting for novel corrosion modelling techniques and accidental damage. The associated uncertainties are considered using statistical sampling from evidence-based distributions. A state-of-the-art deterministic model for ultimate strength calculation is applied using Monte Carlo simulation approach, resulting in the probability of hull failure through a reliability assessment. Wave and still-water bending moments are considered random variables. Two case studies of tanker ships with varying sizes are executed to show the applicability of the proposed framework. The results indicate that proper consideration of corrosion is of high importance, as ageing can significantly increase the probability of failure if accidental damage happens. Therefore, whereas future research and model refinement are discussed, the presented framework can serve for risk-based ship design tool and assess existing structures’ safety.

Monitoring atmospheric corrosion under multi-droplet conditions by electrical resistance sensor measurement

This paper presents a novel approach to investigate atmospheric corrosion kinetics of carbon steel under multi-droplet conditions. A homemade climate chamber has been developed to accurately control and monitor environmental conditions, including temperature (T) and relative humidity (RH), during exposure. Carbon steel corrosion kinetics are monitored with a custom-designed Electrical Resistance (ER) sensor pair. Savitzky-Golay (S-G) based filtering technique has been used for the corrosion signal processing. In parallel, top-view droplet temporal evolution has been recorded by microscopic imaging and analyzed for both droplet size distribution and the solid-liquid contact angle. The droplet size distribution can typically be described with a power-law form curve. The curve shows a decrease in height and a concurrent expansion in width with progressive drying. The introduction of NaCl into the electrolyte and surface roughness variations have also been identified to substantially influence the carbon steel corrosion rate. A strong correlation between the corrosion rate derived from the ER monitoring method and the RH can be observed. This correlation is further analyzed to incorporate the impact of droplet-based electrolyte conditions. This study offers valuable insights into the development of mechanistic and kinetic prediction models for atmospheric corrosion.