October 21, 2021 10:00 a.m.–4:15 p.m. CEST

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COMSOL Day: Corrosion & Electrodeposition

Corrosion is an age-old problem that is now being effectively contained and prevented due to the advent of simulating the participating electrochemical reactions that occur and transport processes that affect them. The same principles can be used to simulate, design, and optimize industrial electrodeposition processes.

COMSOL Day: Corrosion & Electrodeposition will introduce you to new strategies in fighting corrosion and augmenting electrodeposition applications through mathematical modeling. The day will involve a series of invited speakers from industry and research organizations reporting on their experiences simulating corrosion, as well as parallel sessions involving presentations and demonstrations of the COMSOL Multiphysics® software by COMSOL technical staff.

Schedule

9:45 a.m.
Registration
10:00 a.m.

To start, we will briefly discuss the format of the day and go over the logistics for using GoToWebinar.

10:05 a.m.

Simulating engineering applications has long been the domain for simulation experts working at more fundamental levels of physics, such as fluid flow, structural analysis, and electric field theory. While this has served certain industries, such as automotive and aerospace manufacture, it has less history in fields that are described by more complex or multiple physics being coupled together.

Corrosion & electrodeposition are examples of this. Simulating the participating electrochemical reactions that occur and transport processes that affect them are rather complex to model and there is no naturally available tool for your average engineer working with corrosion & electrodeposition systems.

Simulation apps answer this need. Utilizing the theoretical knowledge and modeling experience of a simulation expert, engineers working on oil platforms, underground piping networks, ICCP, and the electrodeposition of copper can access simulation through simulation apps developed by the expert. Find out more during this session.

10:30 a.m.

Harald Osvoll, FORCE Technology Norway

Corrosion damages cost more than 2.5 trillion USD each year worldwide, and cathodic protection is a common method to increase the lifetime of systems prone to corrosion. Modeling and simulation of corrosion and cathodic protection systems can be used to optimize the protection, extend operational life, and reduce costs by orders of magnitude.

FORCE Technology has developed and used CP computer simulations for almost four decades to optimize and verify cathodic protection designs for offshore and land-based installations worldwide.

CP modeling is an important tool for the analysis and evaluation of CP inspection data. This session presents examples of CP modeling analysis of electrical field gradient measurements from our FIGS sensor. These analyses have established the level of anode current; anode consumption; current density; and future state of corrosion protection systems for pipelines, subsea installations, and offshore jacket structures. Optimized/minimized anode requirements and retrofit solutions for life extension are established and verified. This approach has resulted in significant cost savings for offshore life extension projects.

11:00 a.m.

Patrick Namy, SIMTEC

Electrochemistry has a wide field of applications in the industry, like corrosion, electrodeposition, or galvanic protection, for example. In all of these topics, several physical phenomena are involved and need to be considered to precisely understand their different interactions, including charge transport, heat transfer, and CFD. In many cases, all of them need to be considered to optimize the global process. As the French leader of COMSOL Certified Consultants, SIMTEC assists industrial professionals in their research using innovative approaches. SIMTEC has acquired strong experience in electrochemical modeling through its work in several industrial applications. An example of a strong collaboration with our client NAVAL GROUP is presented here. The topic is a localized corrosion by which local cavities, pits, are formed on an initially smooth metal surface and can propagate into the metal under some conditions. A numerical model of this specific type of corrosion is developed in this study. This numerical model is validated through experimental data. Different applications and numerical results are finally presented and discussed to emphasize the use of this type of approach.

11:30 a.m.

The fundamental electrochemical behavior of corrosion and electrodeposition applications stems from the same equations with respect to the kinetic reactions that occur and transport processes that affect them. Despite the desired outcomes being different, the same workflows and strategies can be applied when modeling and simulating both phenomena. In this session, we will provide some examples and demonstrations that will exemplify how such electrochemical processes can be modeled. In addition to this, we will show how the democratization of simulation can be utilized to increase productivity throughout your organization through deploying and integrating simulation apps.

12:15 p.m.
Break for Lunch
Introduction to COMSOL Multiphysics® for New Users

Learn the fundamental workflow of COMSOL Multiphysics®. This introductory demonstration will show you all of the key modeling steps, including geometry creation, setting up physics, meshing, solving, and postprocessing.

1:00 p.m.
Parallel Session
Galvanic Corrosion

Galvanic corrosion occurs when two metals in electrical contact are also in the presence of an ion-conducting and sometimes hostile medium. The modeling of galvanic corrosion provides important insights into the choice of materials and their design, including on how they are joined and how they will eventually be affected by their surrounding environment. The session will specifically look at modeling different subsets of galvanic corrosion, atmospheric corrosion, localized (pitting and crevice) corrosion, and under-deposit corrosion.

Electrodeposition

Deposition of thin metal layers driven by electrochemical reactions is a common method in manufacturing industries, from the anodization and electrogalvanization of metals, semiconductor manufacture, and deposition of copper circuits in the electronics industry to the electropolishing of household appliances and jewelry. This session will guide you through the different aspects of modeling electrodeposition and show how simulation can be used to optimize the deposition process.

1:45 p.m.

Tommy Zavalis, RISE Research Institutes of Sweden

The cathodic protection of infrastructure is many times complex to design in a manner that accounts for both small- and large-scale objects. Mathematical simulations enable faster optimization of the protection and provides in-depth understanding of the system. The atmospheric corrosion of metallic materials is tested extensively using accelerated corrosion tests (ACTs) in climate chambers. Mechanistic (or physics-based) models can be used to expand the test matrix and to evaluate and improve existing ACTs.

2:15 p.m.

Thorsten Eichler, CORR-LESS Isecke & Eichler

A wide range of parameters was investigated by numerical calculations concerning their impact on the DC stray current corrosion of reinforced concrete (RC) structures. A simplified model geometry was used to extract the relevant parameters and their interaction in terms of stray-current‐affected structures. This study mainly focuses on RC structures that are fitted with cathodic protection installations. The findings reveal a complex interaction between the investigated parameters. The possible relevance of further parameters, which is not the subject of this study, was emphasized.

2:45 p.m.
Parallel Session
Tech Café: Handling Large Models

When modeling real-life geometries, such as offshore structures, plants, long pipelines, or the details found within car designs, models tend to increase both in size and complexity. Handling large geometries and complex models is an important aspect of modeling, where efficiency can be increased and computational time can be reduced significantly by applying methods for CAD defeaturing or utilizing cluster computing. This Tech Café will guide you through some of the built-in features in COMSOL Multiphysics®, where you can learn how to be more efficient when handling large models.

Tech Café: Galvanic Electrode Deformation

A major aspect to consider when modeling galvanic processes is the fact that the overall behavior of the system varies once anodic and cathodic surfaces change or deform as a result of their corrosion or due to the films of other metals and salts that can be deposited upon them. Edge effects, dendritic formations, inclusions, and other space and electrocatalytic aspects of the system can change the overall electrochemical behavior of the system — sometimes quite significantly, even if in the micrometer or millimeter scale. During this Tech Café, we will discuss which aspects of electrode change and deformation should be considered and the choices that can be made to efficiently encompass these effects when modeling such systems.

3:30 p.m.
Parallel Session
Cathodic Protection

Cathodic protection is a common method to protect major land-based and offshore installations of steel-based structures. The Corrosion Module has a variety of features that support the simulation of cathodic protection systems through the use of either sacrificial anodes (SACP) or impressed currents (ICCP). In this session, we will show you how to build an efficient model of a cathodic protection system and give insight into how to improve cathodic protection designs.

Pulsed Plating and Transient Methods

Achieving a high-quality plating of complex geometries with uniform deposition thickness, desired grain size, and minimal amounts of defects is the ultimate goal for a deposition process. This session will show that by understanding the physics of the process in the context of your geometry and your electrolyte, it is possible to design advanced pulsed plating processes with current duty cycles that result in smooth and uniformly plated surfaces.

4:15 p.m.
Closing Remarks

COMSOL Speakers

Bertil Nistad
Technology Manager
Bertil Nistad currently works as a technology manager at COMSOL in Norway, and has participated in the development of the Corrosion Module. Before he joined COMSOL in 2009, he studied at NTNU, where he received his PhD in electronics and metamaterials. In 2017–2018, he worked as a principal engineer at FORCE Technology on different tasks, mostly concerning cathodic protection simulations.
Henrik Ekström
Technology Manager, Electrochemistry
Henrik Ekström is the technology manager for electrochemistry at COMSOL. Prior to joining COMSOL in 2010, Henrik worked at various fuel cell startup firms in Sweden. He received his PhD in chemical engineering from the Royal Institute of Technology, Stockholm.
Nikolai Høiland Ubostad
Application Engineer
Nikolai Ubostad works as an applications engineer at COMSOL Norway. He started in 2019, having received his PhD in mathematics from the Norwegian University of Science and Technology.
Phil Kinnane
Senior VP of Sales
Phil Kinnane is the senior VP of sales at COMSOL, Inc., and has been with COMSOL since 2000. Previously, he worked in industry and has modeling and simulation experience within a variety of engineering fields. He earned his PhD in electrochemical engineering from the Royal Institute of Technology (KTH), Stockholm.
Jacob Yström
Technology Director
Jacob Yström is the technology director of numerical analysis at COMSOL. He has been the lead developer for the solver technology at COMSOL since 2005. He received his PhD in numerical analysis from the Royal Institute of Technology, Stockholm.
Lorant Olasz
Technology Director, External Interfaces
Lorant Olasz joined COMSOL in 2006 and is the technical product manager for the CAD Import and ECAD Import modules, LiveLink™ for CAD products, and LiveLink development team. Previously, he was a product specialist in structural mechanics. He received his PhD in solid mechanics from the Royal Institute of Technology, Stockholm.
Kiran Deshpande
Technical Product Manager
Kiran Deshpande works as a product specialist in the electrochemical development team at COMSOL. He received his PhD in chemical engineering from the University of Sheffield. Prior to joining COMSOL in 2012, Kiran worked as a senior researcher at General Motors Global R&D, Bangalore, for 5 years.
Andrea Vågen Edvardsen
Application Engineer
Andrea Vågen Edvardsen works as an applications engineer at COMSOL in Norway. She joined COMSOL in 2019, after graduating from the Norwegian University of Science and Technology with an MSc degree in mechanical engineering.
Erlend Kristiansen
Application Engineer
Erlend Kristiansen currently works as an applications engineer at COMSOL in Norway. Previously, he studied control engineering at NTNU, where he received his MSc degree in 2000. Before joining COMSOL in 2012, he worked within both academics and various industries.
Johannes Schumacher
Applications Engineer
Johannes Schumacher works as an application engineer at Comsol Multiphysics GmbH. He studied chemistry at the Friedrich-Alexander-University Erlangen-Nürnberg, where he investigated platinum deposition in nanoporous alumina. For his doctorate at the Georg-August-University Göttingen, he worked with lipid bilayers and developed nanoscale porous support structures for cell membrane models.

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October 21, 2021 | 10:00 a.m. CEST (UTC+02:00)
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Invited Speakers

Harald Osvoll FORCE Technology Norway AS

Harald Osvoll has extensive experience within the field of corrosion, materials, and corrosion protection. He is recognized as an authority in offshore cathodic protection (CP) and serves in various professional committees. He has acquired substantial expertise in the computer modeling of CP systems. He was instrumental in developing the SeaCorr™ software, which is the CP simulation software with the longest track record in the world. His many years in the field has earned him extensive knowledge on the actual performance of CP systems, which has given him a very good basis for carrying out cost-effective CP retrofits.

SeaCorr is a trademark of FORCE Technology.

Patrick Namy SIMTEC

Patrick Namy is an engineer who graduated from ENSIMAG in 2001, earning his PhD in applied mathematics in 2004 from Joseph Fourier University. His thesis, for which he received an award, was about modeling living systems. Patrick is the founder and CEO of SIMTEC, which was created in 2006. He is passionate about mathematical and computer science applications to physics. He particularly enjoys conveying his knowledge to SIMTEC clients in order to help them become self-sufficient users of the COMSOL Multiphysics® software.

Tommy Zavalis RISE Research Institutes of Sweden

Tommy Zavalis is a researcher at the RISE Research Institutes of Sweden in the Material and Production division of the Corrosion department, on the Vehicles and Surface Protection unit. He focuses on simulations and mathematical modeling for studies of atmospheric corrosion and cathodic protection. Tommy holds a PhD in chemistry and chemical engineering from The Royal Institute of Technology (KTH). He has experience within multiphysics modeling of electrochemical systems, incorporating interactions of chemical, electrochemical, and thermal processes. He has advanced modeling knowledge of corrosion and batteries.

Thorsten Eichler CORR-LESS Isecke & Eichler Consulting

Thorsten Eichler is a managing partner of the CORR-LESS Isecke & Eichler Consulting company, with expertise in corrosion and corrosion protection of reinforced concrete, underground installations, and offshore constructions. He is a doctor of engineering from the RWTH Rheinisch Westfälische Technische Hochschule Aachen, with an extensive research background within the field of corrosion and electrochemistry.