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51316-7800-Using predicted corrosion damage to determine stress concentration fracture and crack growth

Product Number: 51316-7800-SG
ISBN: 7800 2016 CP
Author: Tim Froome
Publication Date: 2016
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Structures subject to corrosion damage are likely to develop stress concentrations on the damaged surfaces and these stress concentrations may lead to initiation of cracks and possible crack growth.Simulation of the galvanic effects leading to corrosion has been successfully used for many years to assist design of cathodic protection systems for marine vessels offshore structures and pipelines. Such simulation takes account of the properties of the electrolyte as well as the structural materials to determine electric fields within the electrolyte attenuation in the return path and the surface current densities and potentials.If dissimilar materials are present or a CP system is not adequately designed it is likely that areas will exist where anodic current flows from a structural surface into the electrolyte so causing mass loss from the surface. The magnitude of the anodic current density is directly proportional to the rate of mass loss from the surface and can be used to determine surface shape change.Such shape change generally results in indentations which from a stress analysis point of view act as stress-raisers. Simulation to determine magnitude of the stress concentration can identify most likely sites for crack initiation. The possibility of crack growth and the time taken for the growth can be determined using fracture and crack growth simulation.This paper explores the combined use of galvanic simulation and fracture/crack growth simulation.Firstly the paper uses galvanic simulation to investigate the influences of parameters including electrolyte thickness and conductivity on rate of corrosion for a galvanic cell caused by a metallic sample in contact with a more noble material. The two materials will be exposed to differing environmental conditions including immersion in a deep layer of electrolyte exposure to thick layers of electrolyte at junctions between the different materials and to thinner layers of electrolyte which might be caused by condensation. The paper reaches conclusions regarding the type of environment that is likely to produce higher penetration rates and where this is likely to occur.Secondly having removed material from the surface (corresponding to corrosion occurring over a given exposure time) the paper uses stress simulation to evaluate the stress concentrations and then goes on to initiate cracks in the potential problem areas determine stress intensity factors and identify vulnerability to fatigue failure. This crack growth takes into account the corrosion damage and inherently includes local stress concentration due to the damaged surface. In the crack growth simulation the full crack path and direction are determined along with the fatigue life.This paper provides a methodology that can be used by design engineers to identify possible problems on a structure giving scope to change designs and so reduce possible failures and in-service repair costs. This methodology identifies areas of the structure that have the greatest risk of damage - which may not be obvious without combined corrosion and fracture simulation; and so provides more informed targeting of locations where “what if” fracture mechanics should be applied.
Structures subject to corrosion damage are likely to develop stress concentrations on the damaged surfaces and these stress concentrations may lead to initiation of cracks and possible crack growth.Simulation of the galvanic effects leading to corrosion has been successfully used for many years to assist design of cathodic protection systems for marine vessels offshore structures and pipelines. Such simulation takes account of the properties of the electrolyte as well as the structural materials to determine electric fields within the electrolyte attenuation in the return path and the surface current densities and potentials.If dissimilar materials are present or a CP system is not adequately designed it is likely that areas will exist where anodic current flows from a structural surface into the electrolyte so causing mass loss from the surface. The magnitude of the anodic current density is directly proportional to the rate of mass loss from the surface and can be used to determine surface shape change.Such shape change generally results in indentations which from a stress analysis point of view act as stress-raisers. Simulation to determine magnitude of the stress concentration can identify most likely sites for crack initiation. The possibility of crack growth and the time taken for the growth can be determined using fracture and crack growth simulation.This paper explores the combined use of galvanic simulation and fracture/crack growth simulation.Firstly the paper uses galvanic simulation to investigate the influences of parameters including electrolyte thickness and conductivity on rate of corrosion for a galvanic cell caused by a metallic sample in contact with a more noble material. The two materials will be exposed to differing environmental conditions including immersion in a deep layer of electrolyte exposure to thick layers of electrolyte at junctions between the different materials and to thinner layers of electrolyte which might be caused by condensation. The paper reaches conclusions regarding the type of environment that is likely to produce higher penetration rates and where this is likely to occur.Secondly having removed material from the surface (corresponding to corrosion occurring over a given exposure time) the paper uses stress simulation to evaluate the stress concentrations and then goes on to initiate cracks in the potential problem areas determine stress intensity factors and identify vulnerability to fatigue failure. This crack growth takes into account the corrosion damage and inherently includes local stress concentration due to the damaged surface. In the crack growth simulation the full crack path and direction are determined along with the fatigue life.This paper provides a methodology that can be used by design engineers to identify possible problems on a structure giving scope to change designs and so reduce possible failures and in-service repair costs. This methodology identifies areas of the structure that have the greatest risk of damage - which may not be obvious without combined corrosion and fracture simulation; and so provides more informed targeting of locations where “what if” fracture mechanics should be applied.
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