Multphysics SIMulations of COrrosion-FATigue

Project Information

SIMCOFAT

Grant agreement ID: 101031287

DOI

10.3030/101031287

Project closed

EC signature date 5 March 2021

Start date 1 September 2021

End date 31 August 2023

Funded under

• EXCELLENT SCIENCE - Marie Skłodowska-Curie Actions

Total cost

€ 212 933,76

EU contribution

€ 212 933,76

Coordinated by

IMPERIAL COLLEGE OF SCIENCE TECHNOLOGY AND MEDICINE
United Kingdom

Periodic Reporting for period 1 - SIMCOFAT (Multphysics SIMulations of COrrosion-FATigue)

Reporting period: 2021-09-01 to 2023-08-31

Summary of the context and overall objectives of the project

The project SIMCOFAT addresses a fundamental challenge in materials engineering, namely the reliable prediction of corrosion-fatigue cracking in critical structures and components. Corrosion-fatigue is a complex phenomenon that occurs when materials, often used in demanding environments such as offshore wind turbines and aerospace components, are subjected to cyclic loading in the presence of corrosive agents. The combined action of mechanical stress and environmental degradation can lead to crack initiation and propagation, and ultimately the failure of the integrity and safety of structures. In this context, the overall objective of the project is to develop a comprehensive numerical framework that can predict corrosion-fatigue damage and crack propagation, incorporating microstructural information and environmental factors. This framework is expected to offer a paradigm shift in the field of corrosion science, promising more accurate, informed, and cost-effective strategies for the management and maintenance of critical infrastructure.
The specific objectives of the project can be summarized as follows (1) To develop advanced multiscale modelling tools capable of capturing the microstructural factors that affect corrosion-fatigue behaviour. By integrating microstructural information, such as grain boundaries and material properties, into the modelling process, this project aims to provide a more accurate representation of real-world corrosion-fatigue phenomena. (2) To create a numerical framework that seamlessly integrates fatigue and corrosion models. By linking these two phenomena, we aim to provide a more complete understanding of how corrosion processes interact with mechanical fatigue, ultimately leading to crack initiation and propagation.
In summary, this project is driven by a profound need for advanced tools to predict and mitigate the effects of corrosion-fatigue on critical structures. It combines state-of-the-art modelling techniques, real-world validation, and broad impact to provide a holistic solution to the challenge of corrosion fatigue.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Since the beginning of the project, significant progress has been made in achieving the proposed objectives and milestones. Initial work focused on the development of a novel micromechanical modelling framework using phase field methods for dissolution of materials. The implementation of fast Fourier transform (FFT) solvers helped to optimize the computational performance of the model, particularly when dealing with large microstructures, a crucial aspect of corrosion-fatigue. This achievement was in line with the first objective and lays the foundation for the entire project. In this project, microstructural data was successfully integrated into the numerical model, which allowed to capture microstructural insights into corrosion-fatigue. Project efforts were expanded to incorporate phase-field fracture methods into the developed microscale modelling framework. This extension allowed to explore crack nucleation, predict potential crack growth and, most importantly, understand the mechanisms leading to structural failure in the presence of corrosion. The development of this comprehensive modelling framework is the key to achieving the second objective, i.e. to seamlessly integrate fatigue and corrosion models. The results of the SIMCOFAT project were presented in conferences: ESMC 2022, GEF 2023, COUPLED 2023 and COMPLAS 2023; as well as openly published in the journals: Model. Simul. Mat. Sci. En., Int. J. Fatigue and Adv. Eng. Softw.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The project has already demonstrated remarkable advances in the field of corrosion and fatigue modelling. By integrating advanced modelling techniques, such as FFT-based solvers and phase field methods for material degradation and fracture, we have established a novel framework that allows to simulate corrosion-fatigue at the microstructure level with a level of detail and accuracy not previously achieved. SIMCOFAT project’s approach allows to represent microstructural phenomena, which are key to understanding localized corrosion and its impact on fatigue life. By focusing on the entire corrosion-fatigue process, from nucleation to dominant crack propagation, this project is pushing the boundaries of knowledge and modelling capabilities in this area.
The potential impact of this project goes far beyond academia. The ability to reliably predict corrosion-fatigue cracking in engineering structures is of immense importance to a variety of industries, particularly those in the aerospace, energy, and maritime sectors. The implications of the project also extend to future research and innovation. The numerical tools and methodologies developed provide a solid foundation for future research. Researchers from diverse fields will be able to build on this work to explore new frontiers in corrosion science and materials engineering.

Sigle edge fatigue crack