Multi-physics simulation of mechano-electrochemical bidirectional coupling interaction of galvanic corrosion between Al alloy and 316L SS

Abstract Due to the limitations of experimental testing in material size and time scale, this work presents a mechano-electrochemical bidirectional coupling finite element method (FEM) simulation model on account of mechanistic and corrosion kinetics understanding in Al alloy-316L SS galvanic couple. The galvanic corrosion behavior and anodic dissolution deformation of the couple in 3.5 wt.% NaCl solution were analyzed. The effect of external load on galvanic corrosion initiation and propagation was investigated based on Gutman’s theory. The FEM model reveals that the galvanic corrosion is connected with the mechanical damage and the stress concentration coefficient, and highlights the crucial role of corrosion defect in the mechanical behavior of Al alloy. The results show that the external force aggravates the galvanic corrosion at the defects, deteriorating the protection of corrosion products. The thickness of the Al (OH) 3 deposition layer reflects the electrochemical reactivity at different positions on the anode surface. The mechanical damage occurs initially at the corrosion defect and then extends to the middle of the anode. The stress concentration coefficient at the center of the anode gradually exceeds the position of the corrosion defect, resulting in mechanical failure at this position.