Lesson: Pitting corrosion simulation in Abaqus
Analyzing and predicting pitting corrosion is important because it helps in detecting and diagnosing corrosion early. So, it can prevent severe damage to structures. For instance, we can predict and detect this phenomenon and enhance the durability and safety of structures such as storage tanks, shafts, tubes, pipes, and other industrial components.
Not predicting pitting corrosion correctly can have significant consequences, including:
- Reduced Fatigue Strength: this phenomenon can reduce the fatigue strength of materials, such as the Al2024 alloy, by at least 40% at 10^5 cycles.
- Formation of Fatigue Cracks: it can lead to the nucleation and propagation of fatigue cracks under sustained cyclic loading.
- Decreased Material Strength: The perforations caused by pitting result in increased stress concentrations. They reduce the strength properties of the material.
- Shortened Fatigue Life: it can reduce fatigue lives by a factor of 6-8.
- Increased Risk of Structural Failure: In critical applications like aircraft and offshore structures, failure to predict pitting corrosion can lead to unexpected structural failures due to the degradation of material strength and fatigue life.
Based on the provided details, the inability to accurately predict pitting corrosion can compromise the safety and integrity of structures and components. So, early detection allows for planning preventive maintenance. It helps us to extend the life of materials and structures, and avoiding catastrophic failures such as pipes bursting or reduced resistance to internal pressure. Predicting and analyzing pitting corrosion experimentally does come with several limitations, including:
- Complexity of Corrosion Phenomenon:
Corrosion is a highly complex phenomenon that is difficult to predict precisely due to the numerous variables involved, such as environmental conditions and material properties.
- Empirical Nature of Anti-Corrosion Measures:
Much of the anti-corrosion measures adopted in practical applications are derived from experience and empirical evidence rather than deterministic models.
- Non-Trivial Characterization:
Deterministic characterization of pitted surfaces is a non-trivial task due to the intricate physical and chemical interactions between the material and the environment.
- Variability in Pit Geometry:
The geometry of corrosion pits can vary significantly, making it challenging to create accurate and consistent experimental models.
- Limited Literature:
There is currently very limited literature regarding the systematic characterization of pitted surfaces or the efficient use of numerical methods to assess its effects. Numerical simulations play a crucial role in predicting pitting corrosion by providing reliable results that can be compared with experimental data. That is to say, these simulations help in understanding the effects of this phenomenon on various properties of materials. For example, simulations have shown that corrosion pits slightly increase transverse vibrations. By using finite element methods (FEM), numerical simulations can model the geometrical properties of corroded structures and predict how different factors, such as the amount and location of corrosion, affect the material’s behavior. This predictive capability is essential for planning maintenance and preventing failures in industrial applications.
Abaqus is a commercial finite element software that helps to analyze pitting corrosion by providing accurate results for the stress distribution around the pits. Based on the papers in the literature, Abaqus pitting corrosion simulation shows accurate results with a maximum error of only 8% for analyzing models with surface pits. So, the software can be used to develop the geometry of the pits. In other words, it allows for a detailed analysis of the stress concentration and the effects of pit geometry on the material’s behavior under load.
The tutorial helps you in understanding the impact of pitting corrosion and developing strategies to mitigate its effects, thereby enhancing the durability and safety of structures. To do so, we have discussed the Abaqus pitting corrosion simulation aspects for analyzing the plates and shafts.
The first python script is developed to model pitting corrosion on plates. The simulation considers random distributions and sizes of pits. By running the scripts, you can choose different options for the randomness, size and number of pits on a single plate, based on your project.
The second script is developed for simulating the pitting corrosion on the shafts, using Abaqus CAE. To do so, 10-node quadratic tetrahedron elements (C3D10) are chosen for the finite element analysis. Using the provided script, pits can be modeled at different positions and shapes on a shaft.
You can import your models with desired geometry, solver, and boundary conditions, in Abaqus, and run the script to generate pits on. So, the scripts are general and help you analyze pitting corrosion, considering the randomness, in your model.
Workshop 1: Pitting Corrosion Analysis on Plates
We have developed the first python script to perform the Abaqus pitting corrosion simulation for plates. The simulation considers random distributions and sizes of pits. In conclusion, by running the scripts, you can choose different options for the randomness, size and number of pits on a single plate, based on your project.
Workshop 2: Modeling Pitting Corrosion on Shafts
We have developed the second script to perform the Abaqus simulation for the shafts. To do so, 10-node quadratic tetrahedron elements (C3D10) are chosen for Abaqus pitting corrosion simulation. That is to say, using the provided script, pits can be modeled at different positions and shapes on a shaft.
You can import your models with desired geometry, solver, and boundary conditions, in Abaqus, and run the script to generate pits on. So, the scripts are general and help you to perform the simulation, considering the randomness, in your model. In conclusion, the scripts will simplify the simulation and helps you to perform pitting corrosion analysis in a simple while accurate manner.
Xylona –
The fourth and fifth workshops in this package demonstrate the powerful capabilities of the HETVAL subroutine in Abaqus. It shows how the heat flux can be defined as a function of user-defined state variables, allowing for the solution of various problems involving parameters like damage or cure degree. The step-by-step instructions provided in the workshops make it easy to understand and implement this feature. The verification of results ensures the accuracy and validity of the procedure. Overall, this package offers practical examples and valuable insights into using HETVAL for complex simulations.
To enhance your skills in this package, I recommend studying the lesson materials thoroughly and practicing the workshops hands-on. If you have specific questions or need guidance for your project, don’t hesitate to seek consultancy and support from the package provider or experts in the field. Additionally, consider pursuing certification to validate your knowledge and skills in using the HETVAL subroutine. Continuous learning, staying updated with the latest developments, and engaging with the community of professionals will help you further enhance your skills in this domain.
Zuleika –
The fifth workshop in this package tackles a realistic and complex problem: the simulation of the curing process in fiber-reinforced composite laminates. This workshop provides a step-by-step guide on using the HETVAL subroutine in Abaqus to simplify this challenging process. The curing process is crucial in the production of fiber-reinforced composites, and numerical simulation offers a cost-effective way to optimize it. The workshop explains the thermochemical model used for simulating the curing process and extracting parameters like the degree of cure and temperature distribution within the composite. The integration of Abaqus subroutines like HETVAL and DISP enhances the capabilities of the software for such simulations.
To enhance your skills in this package, I recommend delving into the second lesson, which provides a comprehensive understanding of fiber-reinforced composites, their manufacturing processes, and the significance of the curing process. You can also explore additional resources outside the package to expand your knowledge further. If you have a specific project related to this product, consider reaching out for consultancy to get guidance tailored to your requirements. Obtaining a certificate for completing the lessons and workshops will validate your proficiency. Additionally, continue learning and stay updated with the latest developments in the field to prepare yourself for job opportunities.
Balthazar –
:Lesson 2 of this package offers valuable insights into fiber-reinforced composites (FRCs) and their manufacturing processes. It explains how FRCs are composed of fibers and a matrix, and the role each component plays in providing strength and durability. The lightweight characteristics, durability, and strength of FRCs make them highly advantageous in various industries. The lesson covers different types of FRCs based on matrix and fiber materials, as well as their applications in industries like aerospace, automotive, and construction.
To enhance your knowledge about this package, I recommend thoroughly studying Lesson 2 to understand the fundamentals of FRCs. If you have specific questions about the curing process in FRCs or the materials used, this lesson provides answers. Additionally, you can explore external resources to further expand your understanding of FRCs and their applications in specific industries. If you have a specific project related to this product, consider seeking consultancy to get expert guidance tailored to your project’s requirements. Obtaining a certificate for completing the lessons will validate your knowledge and skills in this domain, which can be beneficial for job opportunities.