- Conference Article
- 10.5006/c2026-00411
Aerospace Corrosion Simulation: Pristine to Pitted and beyond
- Mar 06, 2026
- Thomas Curtin + 3 more +3
Abstract There has been significant advancement in the development and application of corrosion modeling tools for the aerospace defense industry over the past five years. Easy to use and fast modeling solutions are now available for galvanic design compatibility. These tools use mixed-potential theory and polarization curve crossing principles to determine corrosion rates for bimetallic couples. These same tools support the analytical transformation of polarization curves obtained in bulk electrolytes; creating new data that can be used to model aerospace related thin film environments, more typical of atmospheric exposure. This transformation is achieved using an optimized deconvolution process applied to existing polarization scan data which reduces the experimental testing burden. The industry has also seen significant advancements in the simulation of aircraft component corrosion using physics-based modeling. 3D FEA multiphysics modeling can be used to assess corrosion rates in multi-material assemblies, simulate coating degradation, and model steady-state crevice environments. The advent of this physics-based modeling capability is important when dealing with actual component geometry because the IR drop in the electrolyte film can have significant effects on the spatial distribution and magnitude of corrosion rates. Recent strides have also been made to incorporate corrosion related degradation into model-based simulation engineering tools, making it easier to track damage across the life cycle, and provide critical information to engineers charged with structural integrity decision making. Innovative approaches have been developed to model pitting interaction and perform corrosion fatigue crack propagation simulations using environment representative crack growth kinetics and advanced modeling that supports multi-site damage and short crack growth relationships to better capture near ΔKth behavior. New modeling solutions that simulate different cracking scenarios, found at the boundary of corrosion cavities, are also in the initial stage of development. These new modeling approaches attempt to improve corrosion related damage assessment and advance upon previous ideas in Murakami’s defect √area method and Kondo’s pit-to-crack competition model.
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