Simulation of Corrosion Phenomena in Automotive Components: A Case Study

Area of Science:

• Materials Science
• Computational Engineering
• Electrochemistry

Background:

• Mathematical modeling and software simulations are crucial for understanding and predicting metallic component corrosion.
• COMSOL Multiphysics 5.6 offers validated models for predicting and preventing corrosion in specific geometries.
• Zinc-coated steel is widely used, making its corrosion behavior critical for component longevity.

Purpose of the Study:

• To investigate the corrosion of zinc-coated steel sheets using mathematical modeling and laboratory testing.
• To compare simulation results with experimental data from salt spray tests.
• To refine computational models for accurate prediction of protective zinc layer stability.

Main Methods:

• Utilized COMSOL Multiphysics 5.6 for mathematical modeling of corrosion processes.
• Conducted laboratory experiments involving salt spray tests on zinc-coated steel sheets.
• Analyzed discrepancies between simulation and experimental results to improve model accuracy.

Main Results:

• Simulation results were compared with laboratory test data to estimate the stability of the protective zinc layer over time.
• Identified discrepancies between modeling and empirical tests.
• Developed a computational model for corrosion phenomena applicable to automotive components.

Conclusions:

• Mathematical modeling and simulations, when validated against experimental data, provide a reliable method for predicting corrosion.
• The developed computational model can potentially reduce the need for extensive and costly laboratory testing.
• Refined models enhance the prediction of protective layer lifespan in automotive components.