Numerical Simulation of Galvanic Corrosion between Carbon Steel and Low Alloy Steel in a Bolted Joint

Abstract

The galvanic corrosion of a bolt joint combining carbon steel end plate and low alloy steel bolt was investigated electrochemically in a 1 M HCl solution. The corrosion parameters of the joint components were used for numerical simulation using Comsol Multiphysics software to analyze the galvanic corrosion behavior at the contact zone between the head bolt and the end plate. In this research work we evaluate the variation of the corrosion rate in the steel end plate considered as the anode, in order to determine the lifetime of the bolted assembly used in steel structures. Three materials (20MnCr5, 42CrMo4, and 32CrMoV13) and three bolts (M12, M16, and M20) were tested in two thicknesses of electrolyte 1 M HCl ( = 1 mm, = 20 mm). It is found that the corrosion rate of the anode part (end plate) is higher for 32CrMoV13 materials and it increases if both diameter of the bolt and thickness of the electrolyte increase (Cr(M20) > Cr(M16) > Cr(M12) and Cr( = 20 mm) > Cr( = 1 mm)). This corrosion rate is higher in the contact area between the bolt head and the end plate, and it decreases if we move away from this contact area.

Galvanic corrosion behavior and numerical simulation of 5083 aluminum alloy and Q235 steel in 3.5% NaCl solution

“…Results show that when the cathode/anode area ratios are 1:1, 5:1, and 10:1, the galvanic current density are 16.890 × 10 −6 , 63.308 × 10 −6 , and 111.77 × 10 −6 A/cm 2 , respectively, and the galvanic current increases with increasing cathode/anode area ratio. The cathodic and anodic processes at the electrode–electrolyte interface occur simultaneously, [ 35 ] and the electrons required for the cathodic reduction reaction are equal to the number of electrons provided by the anodic oxidation. [ 36 ] As its area increases, the Q235 steel adsorbs increased oxygen on the surface and undergoes a reduction reaction.…”

FE modeling of the effect of conductivity in galvanic corrosion between different types of stainless steel and carbon steel in a structure bolted joint

“…The risk of galvanic corrosion often justifies a warning against combinations of dissimilar metals in corrosive environments. The corrosion is stimulated by the potential difference that exists between the two metals, the more noble acting as a cathode where some oxidizing species is reduced, the more active metal, which corrodes, acting as the anode (Radouani et al. , 2017, 2021).…”

“…The risk of galvanic corrosion often justifies a warning against combinations of dissimilar metals in corrosive environments. The corrosion is stimulated by the potential difference that exists between the two metals, the more noble acting as a cathode where some oxidizing species is reduced, the more active metal, which corrodes, acting as the anode (Radouani et al, 2017(Radouani et al, , 2021). The corrosion rates (CRs) and the potential distribution over a galvanic couple depend upon the electrochemical properties of the metals, on environmental variables such as temperature, salinity, oxygen content and solution flow, as well as the geometry of the corroding system.…”

Numerical Investigation of the Galvanic Corrosion Behavior of a Joint between Steel and Aluminum Alloys Produced by Friction Stir Joining

“…They varied the conductivity and pH of the electrolytes and reported on the loss of thickness of the anode over time. Radouani et al [ 17 ] investigated the galvanic corrosion behavior of the contact zone between carbon steel and low alloy steel using numerical simulation. They reported on the effects of varying the bolt diameter and the thickness of the electrolyte on the galvanic corrosion behavior of the joint.…”