Simulation of Corrosion Phenomena in Automotive Components: A Case Study

Mathematical modelling and software simulation nowadays are very effective tools for both understanding and predicting corrosion processes and the protection of metallic components. COMSOL Multiphysics 5.6 software provides validated mathematical models that can be used, for a given geometry, as a tool to predict and prevent corrosion of components. The corrosion of zinc-coated steel sheets has been studied in this work by comparing results of the simulations with laboratory tests carried out in a salt spray. Results of both the mathematical modelling and empirical tests give the possibility to estimate the stability of the protective zinc layer over time. The examination of the discrepancies between two analytical methods for the investigation of corrosion phenomena leads to possible modifications in the model in order to reach as much as possible coherence with experimental data. As a final result, a computational model of corrosion phenomena in an automotive component has been reached, allowing in the future to partially substitute laboratory tests, usually being highly time consuming and expensive.

Automated summary

Mathematical modelling and software simulation are effective tools for understanding and predicting corrosion processes. The COMSOL Multiphysics 5.6 software provides validated mathematical models for predicting and preventing corrosion. This study compared simulation results with laboratory tests to investigate the corrosion of zinc-coated steel sheets. The results of mathematical modelling and empirical tests allow estimation of the stability of the protective zinc layer over time. Discrepancies between analytical methods led to modifications in the model for better coherence with experimental data. A computational model of corrosion phenomena in an automotive component was developed, which could potentially replace time-consuming and expensive laboratory tests.