Rapid development of lightweight components by virtual corrosion testing

Purpose and goal

The project has contributed to innovation theme 2 "lighter with shorter development time" through parallel development of virtual and experimental testing of the atmospheric bimetallic corrosion of aluminum alloys. The purpose has been to build methods to perform faster and more reliable life-time predictions in service, using a limited amount of testing complemented with simulation. Mechanistic models have been set up and validated for a specific bimetallic coupling against designed experiments and have been used for detailed virtual analysis and corrosion testing.

Expected results and effects

The project has resulted in experimentally validated mechanistic models describing the galvanic corrosion between aluminum alloy 1050 and 316L stainless steel under atmospheric conditions. For this material combination simulations can be performed to explore the underlying processes of the galvanic couple in detail and corrosion testing improvements. The developed strategy for parametrization and validation is now available to be used to expand the models’ window of usage in terms of exposure condition, sample design, and other material combinations.

Planned approach and implementation

The project involved the design of both virtual and experimental tools. Since the virtual ones used a mechanistic modelling approach a strategy for parameterization and validation of the model was formulated and followed. A critical part of the strategy was to fit the model to experimental observations made on a designed validation cell at controlled exposure. A sensitivity analysis was thereafter performed with the model to fully explore the model limitations. Following this, both detailed analysis of the galvanic couple and virtual corrosion testing was possible.

External links

Öppen projektbeskrivning på RISE hemsida.