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

STAR AR-CCM+ CCM+ Cor orrosion osion Feb 2015

What is STAR-CCM CM+ Engine En neering ering simula ulati tion on inside ide a single gle integra egrated ed envi vironment nment Lon ong Tradit ition ion in Computa putati tional onal 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

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, Jonathan G. Dudley Air Force Research Lab powerful multi-physics framework tool set for a variety of fields.” 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 osion Different erent mechani chanism sms – Galvanic – Atmospheric 3% GNP – Flow induced – Stress induced – Many more Accelerated Testing Corrosion Costs Flow Accelerated Corrosion (FAC) Cathodic Protection (CP) Learn From Customers → Long Term Development

Corr rrosion osion Modeli ling (a) Empirical (b) Mechanistic Corrosion Proxies Secondary & Tertiary Current fit data ideal limited prediction predictive fast specialized slow Corrosion Depth 𝑺𝒗𝒕𝒖 𝑮𝒇 𝟑+ 𝑮𝒇 𝟑+ + 𝟓𝑷𝑰 − → 𝑮𝒇(𝑷𝑰) 𝟑 𝑫𝒃𝒖𝒊𝒑𝒆𝒋𝒅 𝟓𝒇 − + 𝑷 𝟑 + 𝑰 𝟑 𝑷 → 𝟓𝑷𝑰 − d = At n 𝑩𝒐𝒑𝒆𝒋𝒅 𝒇 − 𝟑𝑮𝒇 → 𝟑𝑮𝒇 𝟑+ + 𝟓𝒇 − Time

Flow Accelerat erated ed Corrosion: osion: Empiri pirical al Norsok 2005 𝑏+𝑐∗log 𝑔 𝐷𝑃2 𝐺 𝑞𝐼 Gabetta, Margarone, and Bennardo. Offshore 𝑇 𝐷𝑃2 𝑑 CR t = K t * 𝑔 Mediterranean Conference and Exhibition 2011, Ravenna, 𝑇 0 Italy 2011 Flow 7

Flow Accelerat erated ed Corrosion osion 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 ough an elbow Increa crease se of mass s transf nsfer er rate in air throu ough gh pipe bends nds – Simulations of Wang Re = 9e4 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 = 3.9e5 Re = 9e4 9

Test st Chamber mber Evapor orati ation/Cond on/Conden ensation sation Velocity Flui uid d Film m model odel S K- e tur RAN ANS 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 on and run unof off Chambe amber hum umidity idity and tempera perature ture differ er from om inlet Temperature Humidity Film Thickness

Can also o 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 𝑺𝒗𝒕𝒖 𝑮𝒇 𝟑+ 𝑫𝒃𝒖𝒊𝒑𝒆𝒋𝒅 𝑮𝒇 𝟑+ + 𝟓𝑷𝑰 − → 𝑮𝒇(𝑷𝑰) 𝟑 𝟓𝒇 − + 𝑷 𝟑 + 𝑰 𝟑 𝑷 → 𝟓𝑷𝑰 − 1 = A Primary Current 𝒇 − 𝑩𝒐𝒑𝒆𝒋𝒅 Distribution 𝟑𝑮𝒇 → 𝟑𝑮𝒇 𝟑+ + 𝟓𝒇 − Ohm’s Law 2 = A+B Secondary Current Distribution Surface • (A) Electrolyte resistance between Reactions electrodes 3 = A+B+C • (B) Charge-transfer resistance of Tertiary Current reactions at the electrode surfaces Distribution Ion Transport • (C) Concentration dependent surface reactions

Secondar ndary y Curren rent t Dist strib ibut ution ion 1. 1. Ohm’s Law 2. 2. El Electr trode de Reacti tions ons – v9.04 Current-potential relationship via • Butler-Volmer • Tabular polarization curve Polarization Curve 1 Measured Current Anodic Potential Cathodic 0 1.00E-07 1.00E-05 1.00E-03 1.00E-01 1.00E+01 1.00E+03 Potential i E -1 Absolute Current Position 13

Elec ectr troplat oplating Corr rrosi osion on prot otecti ection on Decora corati tive e plating ng Cr 3+ 14

Cath thodic odic Protection ection Too much corrosion  Challenge: Eliminate stray current corrosion in a boxcooler (CuNi heat exchanger) caused by a cathodic protection system Too little corrosion - biofouling

Cath thodic odic Protection ection Isolated  Challenge: Eliminate stray current corrosion in a boxcooler (CuNi heat exchanger) caused by a cathodic protection system  Solution: Simulate the electric field in seawater driven by 5 different coated and uncoated metals Boxcooler is electrically isolated from the ship’s hull RED = high corrosion BLUE = possible biofouling

Cath thodic odic Protection ection Isolated  Challenge: Eliminate stray current corrosion in a boxcooler (CuNi heat exchanger) caused by a cathodic protection system Direct Bond  Solution: Simulate the electric field in seawater driven by 5 different coated and uncoated metals  Resistance Bond Impact: Optimize contact condition between boxcooler and ship hull. Resistance and diode bonds perform best! RED = high corrosion BLUE = possible biofouling 15

Terti tiar ary Curren rrent t Dist stribu ributio tion 1. 1. Ohm’s Law 2. 2. El Electr trode de Reacti tions ons 3. 3. Ion n Transp spor ort – Electrochemical Species – STAR-CCM+ v9.06 – Nernst-Planck equations – Surface Reactions * – Bulk Reactions* O 2 Depletion *By Field Functions in v9.06 𝑷 𝟑 + 𝟓𝑰 + + 𝟓𝒇 − ↔ 𝟑𝑰 𝟑 𝑷 Nernst rnst-Planck anck Eq Equa uation on 𝜖𝒅 𝒋 𝜖𝒖 = −𝛂 ∙ 𝑶 𝒋 Conservation: 𝑶 𝒋 = −𝑬 𝒋 𝛂𝒅 𝒋 + 𝒅 𝒋 𝒘 + 𝒜 𝒋 𝑮𝒗 𝒋 𝒅 𝒋 𝑭 Flux Diffusion Convection Migration 18

3D Corr rrosion osion: : Pa Paint int Delami amination nation  Challenge: Model corrosion driven paint delamination. 19

3D Corr rrosion osion: : Pa Paint int Delami amination nation  Challenge: Model corrosion driven paint delamination. 𝒂𝒐 +𝟑 + 𝟑𝑓 − 𝒂𝒐 ↔  Zinc Solution: Solve ion transport 𝒂𝒐 + 2𝑃𝐼 − 𝒂𝒐(𝑷𝑰) 𝟑 + 𝟑𝑓 − ↔ equations including electrochemical 𝑷 𝟑 + 𝟑𝑰 𝟑 𝑷 + 𝟓𝒇 − 𝟓𝑷𝑰 − ↔ Steel surface reactions in STAR-CCM+. 𝑰 𝟑 𝑷 + 𝟑𝑓 − 𝑰 𝟑 + 2𝑷𝑰 − ↔ 19

3D Corr rrosion osion: : Pa Paint int Delami amination nation  Challenge: Model corrosion driven paint delamination.  Solution: Solve ion transport equations including electrochemical surface reactions in STAR-CCM+.  Impact: Reduce costly testing. 19

Wet et-Etc Etching hing of Copper per with h CuCl 2 Etchant: CuCl 2 , HCl, KCl Mask Cu Species ies Cu +2 Cu +2 , , CuCl uCl + , CuCl Cl 2 , CuCl Cl 3 - , , CuCl Cl 3 -2 , Cl - , H + , K +. +. Sur urfac ace e Reactions ctions −𝟑 + 𝒇 − 𝑫𝒗 + 𝟒𝑫𝒎 − → 𝑫𝒗𝑫𝒎 𝟒 𝑫𝒗 +𝟑 + 𝟒𝑫𝒎 − + 𝒇 − → 𝑫𝒗𝑫𝒎 𝟒 −𝟑 𝑫𝒗𝑫𝒎 + + 𝟑𝑫𝒎 − + 𝒇 − → 𝑫𝒗𝑫𝒎 𝟒 −𝟑 𝑫𝒗𝑫𝒎 𝟑 + 𝑫𝒎 − + 𝒇 − → 𝑫𝒗𝑫𝒎 𝟒 −𝟑 − + 𝒇 − → 𝑫𝒗𝑫𝒎 𝟒 −𝟑 𝑫𝒗𝑫𝒎 𝟒 Etch product distribution

Same me Etch h Profiles iles Alkire: dissolution rate of copper Insufficient information to validate quantitatively