Cor orrosion osion Feb 2015 What is STAR-CCM CM+ Engine En - - PowerPoint PPT Presentation

STAR AR-CCM+ CCM+ Cor

• rrosion
• sion

Feb 2015

En Engine neering ering simula ulati tion

• n inside

ide a single gle integra egrated ed envi vironment nment Lon

• ng Tradit

ition ion in Computa putati tional

• nal Flui

uid d Dynami amics s (CFD) D) Developme elopment nt focuse used d on

– Ease of use – Large models (100+ million cells) – Extensive modeling capabilities – Process integration

What is STAR-CCM CM+

Productiv ductivity ity & Effic iciency iency

STAR-CCM+ significantly increases engineering productivity Spend less time on geometry preparation meshing and model setup

– Consistent, repeatable, and easily automated workflow – Process automation using JAVA macros and simulation assistant.

“STAR-CCM+ is a user-friendly, powerful multi-physics framework tool set for a variety of fields.” Jonathan G. Dudley Air Force Research Lab USAF

Relia liabili bility ty & F Flexi xibil ilit ity

STAR-CCM+ meshing provides

– Superior automation, speed, control and reliability. – Reduction in geometry preparation and meshing time from weeks and months to hours, while delivering a high-quality mesh on complex geometries.

STAR-CCM+ client-server architecture allows fully interactive access to all simulation data and solutions while running.

– The software is deployed as a client that handles the user interface and visualization, and a server which performs the compute operations. When executed in parallel, – STAR-CCM+ is scalable across any number of processors allowing very large analyses to be performed, monitored and manipulated from laptops or lightweight workstations.

Many Types s of Corr rrosion

• sion

Different erent mechani chanism sms

– Galvanic – Atmospheric – Flow induced – Stress induced – Many more

Accelerated Testing Flow Accelerated Corrosion (FAC) Cathodic Protection (CP) Corrosion Costs Learn From Customers → Long Term Development 3% GNP

Corr rrosion

• sion Modeli

ling

(b) Mechanistic

Secondary & Tertiary Current

ideal predictive specialized slow

(a) Empirical

Corrosion Proxies

fit data limited prediction fast

d = Atn Corrosion Depth Time

𝑩𝒐𝒑𝒆𝒋𝒅 𝟑𝑮𝒇 → 𝟑𝑮𝒇𝟑+ + 𝟓𝒇− 𝑫𝒃𝒖𝒊𝒑𝒆𝒋𝒅 𝟓𝒇− + 𝑷𝟑 + 𝑰𝟑𝑷 → 𝟓𝑷𝑰− 𝑺𝒗𝒕𝒖 𝑮𝒇𝟑+ + 𝟓𝑷𝑰− → 𝑮𝒇(𝑷𝑰)𝟑 𝒇− 𝑮𝒇𝟑+

Flow Accelerat erated ed Corrosion:

• sion: Empiri

pirical al

Gabetta, Margarone, and Bennardo. Offshore Mediterranean Conference and Exhibition 2011, Ravenna, Italy 2011

CRt = Kt* 𝑔

𝐷𝑃2 𝑑 𝑇 𝑇0 𝑏+𝑐∗log 𝑔𝐷𝑃2 𝐺 𝑞𝐼

Norsok 2005 Flow 7

Flow Accelerat erated ed Corrosion

• sion Proxies

xies

Gas flow with h Lagrangian rangian wa water r droplets lets Fluid id Film m upon n wall impact act Dissolved d specie ies s modeled d as passiv sive scalar Mass transf sfer r coefficie icient nt predict icts corrosio sion n locatio ion

8

Valid idation ation of Mass transf ansfer er throug

• ugh an elbow

Increa crease se of mass s transf nsfer er rate in air throu

• ugh

gh pipe bends nds – Simulations of Wang

Wang and Shirazi, Int. J. of Heat and Mass Transfer 44 (2001) 1817-1822

– Experiments of Achenbach

Achenbach, Future Energy Production Systems (1976) 327-337

Re = 9e4 Re = 3.9e5 Re = 9e4 9

Test st Chamber mber Evapor

• rati

ation/Cond

• n/Conden

ensation sation

Flui uid d Film m model

• del

RAN ANS S K-e tur urbu bulence lence for air flow Trans nsien ient t si simulation ulation to evaluate relati tive e impor mporta tanc nce e of evapora porati tion

• n

and run unof

• ff

Chambe amber hum umidity idity and tempera perature ture differ er from

• m inlet

Humidity Temperature Velocity Film Thickness

Can also

• simulat

mulate e wet etti ting ng behavior ior

Salt Spray Lagrang rangia ian n & Flui uid d Film lm

Mechanist nistic ic Models ls

3 = A+B+C Tertiary Current Distribution

Ion Transport

• (C) Concentration dependent surface

reactions

2 = A+B Secondary Current Distribution Surface Reactions

• (B) Charge-transfer resistance of

reactions at the electrode surfaces

1 = A Primary Current Distribution Ohm’s Law

• (A) Electrolyte resistance between

electrodes

𝑩𝒐𝒑𝒆𝒋𝒅 𝟑𝑮𝒇 → 𝟑𝑮𝒇𝟑+ + 𝟓𝒇− 𝑫𝒃𝒖𝒊𝒑𝒆𝒋𝒅 𝟓𝒇− + 𝑷𝟑 + 𝑰𝟑𝑷 → 𝟓𝑷𝑰− 𝑺𝒗𝒕𝒖 𝑮𝒇𝟑+ + 𝟓𝑷𝑰− → 𝑮𝒇(𝑷𝑰)𝟑 𝒇− 𝑮𝒇𝟑+

1. 1. Ohm’s Law 2. 2. El Electr trode de Reacti tions

• ns

– v9.04 Current-potential relationship via

• Butler-Volmer
• Tabular polarization curve

Secondar ndary y Curren rent t Dist strib ibut ution ion

13

Potential Position

E i

• 1

1 1.00E-07 1.00E-05 1.00E-03 1.00E-01 1.00E+01 1.00E+03

Potential Absolute Current

Polarization Curve

Measured Current Anodic Cathodic

Elec ectr troplat

• plating

Corr rrosi

• sion
• n prot
• tecti

ection

• n

Decora corati tive e plating ng 14

Cr3+

Cath thodic

• dic Protection

ection

• Challenge: Eliminate stray current

corrosion in a boxcooler (CuNi heat exchanger) caused by a cathodic protection system

Too much corrosion Too little corrosion - biofouling

Cath thodic

• dic Protection

ection

• Challenge: Eliminate stray current

corrosion in a boxcooler (CuNi heat exchanger) caused by a cathodic protection system

Isolated

• Solution: Simulate the electric

field in seawater driven by 5 different coated and uncoated metals

RED = high corrosion BLUE = possible biofouling Boxcooler is electrically isolated from the ship’s hull

Cath thodic

• dic Protection

ection

• Challenge: Eliminate stray current

corrosion in a boxcooler (CuNi heat exchanger) caused by a cathodic protection system

15

Isolated Direct Bond Resistance Bond

• Solution: Simulate the electric

field in seawater driven by 5 different coated and uncoated metals

• Impact: Optimize contact

condition between boxcooler and ship hull. Resistance and diode bonds perform best!

RED = high corrosion BLUE = possible biofouling

1. 1. Ohm’s Law 2. 2. El Electr trode de Reacti tions

• ns

3. 3. Ion n Transp spor

• rt

– Electrochemical Species

– STAR-CCM+ v9.06 – Nernst-Planck equations – Surface Reactions * – Bulk Reactions*

Terti tiar ary Curren rrent t Dist stribu ributio tion

18

*By Field Functions in v9.06

Nernst rnst-Planck anck Eq Equa uation

• n

Conservation:

𝜖𝒅𝒋 𝜖𝒖 = −𝛂 ∙ 𝑶𝒋

𝑶𝒋 = −𝑬𝒋𝛂𝒅𝒋 + 𝒅𝒋𝒘 + 𝒜𝒋𝑮𝒗𝒋𝒅𝒋𝑭

Diffusion Migration Convection Flux

O2 Depletion 𝑷𝟑 + 𝟓𝑰+ + 𝟓𝒇− ↔ 𝟑𝑰𝟑𝑷

3D Corr rrosion

• sion:

: Pa Paint int Delami amination nation

19

• Challenge: Model corrosion

driven paint delamination.

3D Corr rrosion

• sion:

: Pa Paint int Delami amination nation

19

• Challenge: Model corrosion

driven paint delamination.

• Solution: Solve ion transport

equations including electrochemical surface reactions in STAR-CCM+. Zinc

𝒂𝒐 ↔ 𝒂𝒐+𝟑 + 𝟑𝑓− 𝒂𝒐 + 2𝑃𝐼− ↔ 𝒂𝒐(𝑷𝑰)𝟑 + 𝟑𝑓−

Steel

𝑷𝟑 + 𝟑𝑰𝟑𝑷 + 𝟓𝒇− ↔ 𝟓𝑷𝑰− 𝑰𝟑𝑷 + 𝟑𝑓− ↔ 𝑰𝟑 + 2𝑷𝑰−

3D Corr rrosion

• sion:

: Pa Paint int Delami amination nation

19

• Challenge: Model corrosion

driven paint delamination.

• Impact: Reduce costly testing.
• Solution: Solve ion transport

equations including electrochemical surface reactions in STAR-CCM+.

Wet et-Etc Etching hing of Copper per with h CuCl2 Species ies

Cu Cu+2

+2,

, CuCl uCl+, CuCl Cl2, CuCl Cl3

• ,

, CuCl Cl3

• 2, Cl-, H+, K+.

+.

Sur urfac ace e Reactions ctions

𝑫𝒗 + 𝟒𝑫𝒎− → 𝑫𝒗𝑫𝒎𝟒

−𝟑 + 𝒇−

𝑫𝒗+𝟑 + 𝟒𝑫𝒎− + 𝒇− → 𝑫𝒗𝑫𝒎𝟒

−𝟑

𝑫𝒗𝑫𝒎+ + 𝟑𝑫𝒎− + 𝒇− → 𝑫𝒗𝑫𝒎𝟒

−𝟑

𝑫𝒗𝑫𝒎𝟑 + 𝑫𝒎− + 𝒇− → 𝑫𝒗𝑫𝒎𝟒

−𝟑

𝑫𝒗𝑫𝒎𝟒

− + 𝒇− → 𝑫𝒗𝑫𝒎𝟒 −𝟑

Etchant: CuCl2, HCl, KCl

Cu Mask

Etch product distribution

Same me Etch h Profiles iles

Alkire: dissolution rate of copper

Insufficient information to validate quantitatively