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Using Galvanic Modeling and Aerosol Spray Testing to Understand How Changes in Salt Loading Can Impact Atmospheric Corrosion

Picture for Using Galvanic Modeling and Aerosol Spray Testing to Understand How Changes in Salt Loading Can Impact Atmospheric Corrosion
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Corrosion is not just a sustainment concern that impacts the availability and safety of critical structural assets; it is also a damage mechanism that should be considered during the initial design phase. By considering the corrosion process and associated preventive strategies during the design phase it is possible to reduce total ownership cost and improve equipment readiness. The Department of Defense spends more than $23 billion each year to control corrosion on aircraft and other equipment in its operations around the world.

Product Number: 51323-18961-SG
Author: Thomas Curtin, Robert Adey, Andres Peratta, Ryan Butchers, Fritz Friedersdorf, Liam Agnew
Publication Date: 2023
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To accurately assess galvanic performance of dissimilar metal components under atmospheric corrosion we need to predict corrosion rates for galvanic couples covered by thin layer electrolytes that commonly occur in the natural environment. In this study we used finite element models of interdigitated electrode (IDE) sensors to help characterize the changing electrolyte properties on a sensor surface during a salt aerosol spray dosing experiment. Different volumes of a sodium chloride solution were sprayed on electrode grids capable of measuring either solution conductance or galvanic current. Computer models of these electrode grids were developed to predict the relative changes in electrolyte properties occurring as applied salt loading was increased; experimental measurements were used to guide model assumptions. The goal of this approach is to characterize electrolyte properties representative of thin film environments in a laboratory controlled environment. Results from this work provide new insight into the spatial extent of electrolyte films developing under different salt loads during simple relative humidity cycle testing. This work supports advancement in understanding the nature of electrolyte films that may occur in the natural environment and provides further guidance on appropriate domain and boundary conditions to consider in finite-element based atmospheric corrosion models.

To accurately assess galvanic performance of dissimilar metal components under atmospheric corrosion we need to predict corrosion rates for galvanic couples covered by thin layer electrolytes that commonly occur in the natural environment. In this study we used finite element models of interdigitated electrode (IDE) sensors to help characterize the changing electrolyte properties on a sensor surface during a salt aerosol spray dosing experiment. Different volumes of a sodium chloride solution were sprayed on electrode grids capable of measuring either solution conductance or galvanic current. Computer models of these electrode grids were developed to predict the relative changes in electrolyte properties occurring as applied salt loading was increased; experimental measurements were used to guide model assumptions. The goal of this approach is to characterize electrolyte properties representative of thin film environments in a laboratory controlled environment. Results from this work provide new insight into the spatial extent of electrolyte films developing under different salt loads during simple relative humidity cycle testing. This work supports advancement in understanding the nature of electrolyte films that may occur in the natural environment and provides further guidance on appropriate domain and boundary conditions to consider in finite-element based atmospheric corrosion models.

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