Numerical Simulation Based on a ZrO₂-Coated Stainless-Steel Corrosion Experiment

Area of Science:

• Materials Science
• Corrosion Engineering
• Computational Modeling

Background:

• 304 stainless steel is prone to corrosion in chloride environments.
• Surface coatings are crucial for enhancing the durability of stainless steel.
• Understanding the mechanisms of corrosion resistance is vital for material selection.

Purpose of the Study:

• To investigate the corrosion resistance of 304 stainless steel coated with zirconium dioxide (ZrO2).
• To develop and validate a numerical model for simulating electrochemical corrosion.
• To elucidate the effect of ZrO2 coating density on corrosion protection.

Main Methods:

• Sol-gel method for preparing ZrO2 coatings on 304 stainless steel.
• Electrochemical testing in a 5% NaCl solution.
• Finite element method (FEM) for numerical simulation of corrosion processes.

Main Results:

• ZrO2 coatings significantly improved the corrosion resistance of 304 stainless steel.
• The numerical model accurately simulated changes in potential and ion concentrations.
• Coating density was identified as a key factor influencing the protective performance.

Conclusions:

• ZrO2 coatings offer effective corrosion protection for 304 stainless steel.
• The developed FEM model provides insights into corrosion mechanisms.
• Optimizing ZrO2 coating density is essential for maximizing corrosion resistance.