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Development and Testing of a Mechanistic Based Atmospheric Corrosion Prediction System

Picture for Development and Testing of a Mechanistic Based Atmospheric Corrosion Prediction System
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The work here is the culmination of many years of prior effort in the development of an atmospheric corrosion model and accompanying sensors. Atmospheric corrosion is a complicated process where many factors interact to determine if it occurs and its severity. These factors can be separated into
three general categories: environmental, surface salts, and materials.

Product Number: 51323-18962-SG
Author: A.R. Trueman
Publication Date: 2023
$0.00
$20.00
$20.00

A corrosion management system was developed to predict atmospheric corrosion for general and
localized corrosion of steels and aluminum alloys. The system can be extended to other materials and
corrosion types. The corrosion management system is at an advanced prototype stage, with more work
required, mainly in the software components, and is currently being commercialized. The system
consists of two components: a Corrosion and Environmental Monitoring System (CEMS) that collects
environmental data using deployable sensors and datalogging equipment, and the Atmospheric
Corrosion Modelling software (ACM) that uses the CEMS data as well as meteorological and pollutant
deposition data, available online, to make corrosion predictions. These corrosion predictions are not
based on empirical corrosion data, nor corrosion sensors that are difficult to translate into structural
corrosion rates. The ACM system can make predictions for current and future corrosion by using all/or
a combination of sensor, meteorological or pollutant deposition data. Where, ideally CEMSs units are
required for accuracy, but predictions could be made using online data alone, if restrictions limit CEMS
deployments. The system can continuously assess current corrosivity and with meteorological data
randomization future corrosion. The ACM is a science, time-based model that uses electrochemical,
mechanistic, and environmental algorithms to predict corrosion. This allows the model to be deployed
to new locations without long term corrosion testing. However, for validation purposes corrosion
coupons were deployed with the CEMS and their corrosion compared to the ACM predictions, with
excellent agreement between the two. For aluminum pitting corrosion ACM is the only validated model
known to exist. The model predicts corrosion for each wetness period, and thus can be used to assess
causality, that for pitting corrosion is important as individual extended periods of wetness dominated the
damage witnessed.

A corrosion management system was developed to predict atmospheric corrosion for general and
localized corrosion of steels and aluminum alloys. The system can be extended to other materials and
corrosion types. The corrosion management system is at an advanced prototype stage, with more work
required, mainly in the software components, and is currently being commercialized. The system
consists of two components: a Corrosion and Environmental Monitoring System (CEMS) that collects
environmental data using deployable sensors and datalogging equipment, and the Atmospheric
Corrosion Modelling software (ACM) that uses the CEMS data as well as meteorological and pollutant
deposition data, available online, to make corrosion predictions. These corrosion predictions are not
based on empirical corrosion data, nor corrosion sensors that are difficult to translate into structural
corrosion rates. The ACM system can make predictions for current and future corrosion by using all/or
a combination of sensor, meteorological or pollutant deposition data. Where, ideally CEMSs units are
required for accuracy, but predictions could be made using online data alone, if restrictions limit CEMS
deployments. The system can continuously assess current corrosivity and with meteorological data
randomization future corrosion. The ACM is a science, time-based model that uses electrochemical,
mechanistic, and environmental algorithms to predict corrosion. This allows the model to be deployed
to new locations without long term corrosion testing. However, for validation purposes corrosion
coupons were deployed with the CEMS and their corrosion compared to the ACM predictions, with
excellent agreement between the two. For aluminum pitting corrosion ACM is the only validated model
known to exist. The model predicts corrosion for each wetness period, and thus can be used to assess
causality, that for pitting corrosion is important as individual extended periods of wetness dominated the
damage witnessed.

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