Modeling, Validation, and Application of Finite Element Models for the Galvanic Corrosion of Aluminum Alloy 6061-T6 Coupled to Non-Passivating and Passivating Alloys

Abstract

Galvanic corrosion of aluminum alloys coupled to non-passivating and passivating alloys exposed in corrosive environments can cause severe corrosion damage in marine structures. The aim of this study is the development of a finite element model using COMSOL Multiphysics to predict the galvanic interaction of aluminum alloy AA6061-T6 coupled to noble materials. The numerical model is based on anodic dissolution kinetics of AA6061 and cathodic kinetics of Ti6Al4V, 316 stainless steel, and copper determined with potentiodynamic polarization. The model predicts that the cathodic material and the geometry of the galvanic couple both influence the corrosion rate of AA6061, and that the solution composition locally changes over time. In order to account for the time-dependent change in solution chemistry a thorough experimental investigation of the effect of pH and chloride ion (Cl-) concentration on the corrosion kinetics of AA6061 is presented using potentiodynamic polarization. Corrosion kinetics were obtained in sodium sulfate and sodium chloride solutions as a function of pH and chloride ion concentration and implemented in the numerical model. The validation of the model is in progress and will be compared to data of actual galvanic couples exposed in the laboratory and in different atmospheric environments. Acknowledgement: This material is based on research sponsored by the USAFA and University of Hawaii under agreement number FA7000-18-2-0004. The U.S. Government is authorized to reproduce and distribute reprints for Governmental purposes notwithstanding any copyright notation thereon.