[1] Reduction of Ultimate Strength due to Corrosion - A Finite Element

Computational Method
J.M. Ruwan S. Appuhamy, Mitao Ohga, Tatsumasa Kaita & Ranjith Dissanayake, (2011)
Objective of the study
To develop a simplified reliable model which can be used to accurately model corroded
surface of steel plates since it is not easy to collect surface corrosion data on numerous
points
Experimentation
Coupon tensile testing- 26 coupons (21 web & 5 flange) from old steel bridge (100 yrs)
Thickness measurement - Portable 3-D scanning system ( tavg, tmin, st, CV computed)
Experimental results analysis
t
= min
t0

> 0.75 ; Minor

0.75 0.5; Moderate

< 0.5; Severe

u
Ductility ratio , =
y

Figure a: Load-displacement curves.

Numerical analysis of the specimens
FE model adopted ductile fracture criterion proposed by Kavinde et al., (2006) (Stress
modified critical strain (SMCS) model, to evaluate the initiation of ductile fracture;
m

critical
(
P = . exp 1.5
e) m , e
is mean (hydrostatic) stress and

effective (Von Mises) stresses respectively

is toughness index obtained from tensile test of uncorroded specimen.
Ultimate strength values of corroded specimens were calculated according to the above
criterion and compared with experimental values.
Good correlation between experimental and numerical tensile strength values (
R2=0.994 ) observed, thus model was accurate hence used to develop a simplified

analytical model.
Development of a simplified analytical model
The simplified model considered minimum essential data values only.
First, the relation between different corrosion parameters was established
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(1) D =5.2t c ,max ( R =0.963 ) ; t c, max is maximum corroded depth .

1
 2
(2) t avg =t 00.2t c ,max (R =0.799)

*The relation shows very good correlation thus these corrosion condition modelling
(CCM) parameters were adopted in developing the analytical model

Figure b: Analytical model with CCM parameters.

Comparison of Load-displacement curves plotted using the new analytical model and
using experimental data.

Figure c: Comparison of load-elongation curves of proposed analytical model.

Comparison of ultimate load capacities of proposed model and experimental results
showed very good agreement with a coefficient of correlation, R2 = 0.992.
Summary notes
Further research proposed to verify the model: different corrosion conditions, corrosion
levels, environmental conditions.
Ductility not discussed explicitly though post yielding behaviour is reported (ultimate
values).

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 [2] Effect of Severe Corrosion on Cyclic Ductility of Steel
Michel Bruneau and Seyed Mehdi Zahrai, 1997
Introduction
Paper reports 2 parts; noncyclic and cyclic ductility
Non cyclic ductility
Experimentation
Uniformly corroded specimens from flange/web of steel bridge beam
Coupon tests (3 readings averaged)
Results and discussion

Well defined yield plateau doesnt exist for corroded specimens due to varying cross
section area along the specimen/ random corrosion attacks.
Maximum stress attained nearly at the same time thus concluded that static ductility not
affected significantly by corrosion.
Points to note
Study considered only 3 specimen
Uniform corrosion
Similar results reported by the same researchers in their 2003 and 2016 papers.

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 [3] An Overview of Corrosion and Experimental Studies on
Corroded Mild Steel Compression Members
A. Cinitha, P. K. Umesha, and Nagesh R. Iyer, 2014
Test Description
Tensile coupon tests on corroded (accelerated exposure) specimens.
Coupons extracted from and angle (C) and tubular (T) steel section
Considered uniform corrosion
Also compression tests on corroded angle and tube sections.
Experimental results
Specim Fy Fu
t w w(%)
en ID (N/mm2) (N/mm2)
0.99, 05.75,
C-1 0.95, mild 366.77 438.57
mild mild
0.70, 0.83, 30.97,
C-2 287.61 330.9
moderate mild moderate
0.97, 08.28,
C-3 0.95, mild 339.42 396.37
mild mild

1.00,
C-4 - - 399.93 465.76
uncorroded

1.00,
TUC-1 - - 336.5 506.16
uncorroded
0.82, 02.21,
TC-2 0.97, mild 326.21 485.19
mild mild
0.81, 06.74,
TC-3 0.77, mild 254.11 409.18
mild mild
0.89, 04.26,
TC-4 0.83, mild 310.24 468.58
mild mild
0.89, 02.66,
TC-5 0.78, mild 274.06 423.23
mild mild
0.97,
TC-6 0.99, mild 0.6 322.56 491.28
mild
0.62, 0.31, 10.11,
TC-7 74.28 135.93
moderate severe mild

F=Applied load/x-sectional
area using average thickness

Points noted
From these experimental results, though not discussed, it can be observed that there is
some loss in ductility depending on the degree of corrosion.

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 [4] Tensile strength assessment of corroded small scale specimens
Y. Garbatov et al., 2014
Test Description
Considered non-uniformly distributed general corrosion i.e., pitting and general corrosion
combined.
Tensile test coupons obtained from corroded box girder. (accelerated corrosion in real sea
water condition)
Results
Corrosion degradation measurement can be expressed in two ways
(1) Degree of degradation (D%), expresses as (mass lost/mass of intact plate)/100
(2) Thickness loss reports net thickness of corroded specimen
Tensile test assessment
P
e= ; e=
A0 L0

P P
t= = ( 1+ e ) = e ( 1+ e )
A A0

L
t =ln ( )=ln ( 1+ e )
Lo

Residual Thickness (mm)

Specimen D, %
Min Max Mean St. Dev.
B5 66.5 1.6 1.76 1.69 0.08
T6 50.4 2.38 2.48 2.42 0.06
D3 31.9 3.15 3.44 3.26 0.16

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 T E =0.0015 D 20.35051 D + 22 %

2
TS =0.0068 D 2.3599 D + 400 MPa The total ultimate elongation defines
when fracture or ultimate strength
appears
The y-intercepts represents the corresponding material properties for uncorroded
specimen.

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 [5] Void Growth Model and Stress Modified Critical Strain Model to Predict Ductile
Fracture in Structural Steels
A. M. Kanvinde and G. G. Deierlein, 2006
Introduction
Studied two models suitable for implementation through FE analysis to simulate
ductile fracture initiation in steel structures;
Ductile fracture criterion
(1) Stress Modified critical strain (SMCS) model
(2) Void growth model (VGM)
Ductile crack initiation mechanism: Void nucleation, growth and finally coalescence.
Void growth depend on equivalent plastic strain and stress triaxiality
The SMCS model
m
P (
critical
= . exp)1.5
e
m , e
is mean (hydrostatic) stress and effective (Von

Mises) stresses respectively

Model Calibration
To calibrate the model, (i.e., determine value) FE analysis of SNT (smooth notched
tensile) specimen is used.
Notching creates triaxial stress at
critical section where small notch
radius implies higher triaxiality
and vice versa

f, the displacement at fracture initiation is retained as the controlling displacement

for FE analysis.
Stresses and strains corresponding to the critical displacement, f from the notched
region of the specimen are substituted into SMCS criterion to back calculate the
critical toughness parameter

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 [ (
= critical
P / exp 1.5
m
e )]
In the model, fracture initiation is predicted whenever the following criteria is
satisfied over the characteristic length during the FEM load history;
critical
p P > 0

[6] Development of an Efficient Maintenance Strategy for Corroded Steel Bridge

Infrastructures
J. M. R. S. Appuhamy ; M. Ohga ; T. Kaita3; P. Chun4; and P. B. R. Dissanayake
1 2

Experimentation
Utilizes results from tensile coupon testing.
Corroded surface measurement 3D coordinate data values obtained using a portable 3D
laser scanning system ( Statistical thickness parameters (tavg, tmin, st, CV) computed)
Estimation of residual yield and tensile strengths

Py,= yield load; Pb, = tensile load; B= uncorroded

width, y, b= yield and tensile stress of corroded-
free plate

How to estimate t*eff, since P values not easily obtained for structures in use

8
 ---(1st graph)

----(2nd graph)

(generalized)

Using best coefficients as deduced from the 3rd graph

Numerical analysis
FE model employed the derived
effective thickness.
SMCS model (Kanvinde, 2006) was used
But,
to predict ductile fracture
Comparison between experimental and
analytical results using the model
showed good agreement.
Tests to determine the
effect of varying measurement intervals
were conducted.
As degree of corrosion
increased, the fineness of the mesh
greatly affected the results.
Development of enhanced
analytical model...(as summarized in
paper 1)

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 [7] Study on the degradation of mechanical properties of corroded steel plates based
on surface topography
G. Qin, et al. (2016)
Introduction
Degradation laws of mechanical properties of corroded steel plates studied
Steel plate coupons from plates subjected to accelerated corrosion used
Characteristics of corroded surface measured by 3-D morphology observation instrument
Relationship between surface characteristic parameters and corrosion rate was established
Stress-strain curves obtained through monotonic tensile tests
Mechanical properties of actual steel corroded plates studied by numerical simulation
using Geomagic Studio (for handling numerous 3D data points) and ANSYS
Experimental results
Surface topography (Using 3-D morphology observation instrument)

From 3D measurement, corrosion data such as void volume ratio (V w), average (Dmean)
and maximum (Dmax) corrosion depth, were obtained.
The relationship between corrosion rate and the surface characteristic parameters was
established graphically
Tensile tests Coupons (Experimental and FEM-ANSYS)

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 Fig. a. Relationship of fracture strain with
corrosion rate
Note curve plotting uses min cross-section area of
the coupon i.e., variation of surface topography not
considered in detail

[8] Ultimate strength assessment of rectangular steel plates subjected to a random

localised corrosion degradation
J.E. Silva, Y. Garbatov, C. Guedes Soares, 2013
Objective
Model structural degradation and estimate residual strength of corroded structures
Corrosion modelling
Spatial varying thickness are generated on the FE model using Monte Carlo simulations.
To accurately simulate the general and pitting corrosion, two types of deterioration were
considered; hexahedron type (varying node thickness of the FE model) surface and
elliptic type (generated using quadratic surface equations).

Ultimate strength
After modelling, regression analysis was conducted on the results and empirical formulae
to predict strength were proposed with respect to the degree of deterioration.

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[1] Plates with uniform corrosion wastages
R2 = 0.999
h0, h, uncorroded and corroded thickness

[2] Plates with random non-uniform hexahedron corrosion

wastages
R2 = 0.999
dod,U is transitional degree of
degradation, ndod,U is time
decay parameter of ultimate strength w.r.t. degradation.
[3] Plates with random non-uniform hemispherical corrosion wastages
R2 = 0.999
C values are constants

[9] Mechanical properties of corroded steel plates under tensile force

A. Kariya et al., 2005
Background information
Previous experiment on residual strength determination has suggested the following
thickness reduction formulae
t R=t avg t (Fujii et al. (1995 buckling strength tests)

t R=t avg +2 t (Kaita et al. (2004) buckling strength tests)

t R=t avg 0.7 t (Muranaka et al. (1998) tensile and fatigue strength tests
In this paper, the effective thickness based on Mises stress was introduced to estimate
tensile strength of corroded plates.
Thickness measurement
Thickness measurement
using laser displacement
gauge (measurement area,
70 mm x 25 mm, interval;
1mm and 0.3 mm (X-, Y-
axis)
Yield and tensile strength
Most corroded specimens
broke near region of
t
smallest average thickness, sa

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 tM
(Mises thickness)
Thickness at broken out area
(point of max stress
concentration)
'
Yield stress y and tensile

strengths 'u and their ratio

with respect to uncorroded
tM
specimens were computed using .
tM
The ratio for different plates having different are close to unity implying using
tM
, its possible to treat the corroded plate as
corrosion-free plate
tM
For in-service structures can be estimated using
t sa
(correlation coefficient 0.97)
Estimation of elongation and ductility
Elongation was measured using extensometer
t
With increased corrosion/surface irregularity (
values), yield strength becomes obscured and elongation
decreases (ductility decrease)
When COV of thickness of corroded plate is more than
0.05, the elongation at maximum force deteriorated
significantly.

Variation of plastic deformation capacity with

respect to COV of plate thickness was derived as;

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 1
=
y (0.03+ 0.8CV )

[10] Influence of pitting corrosion on strength of steel ships and offshore

structures
Marek Jakubowski, 2011
Introduction
A review paper based on Japanese publications
Presents finding on static/quasi-static residual strength estimations due to uniform and
pitting corrosion
Corrosion effects on the structure
(i) reduction of the average material thickness that influence the nominal stress;
(ii) pitting-corrosion-induced roughness of the material surface that leads to local stress
concentrations at some locations at the surface.
Results for tensile testing on pitted steel
a) Load-displacement relation (adapted from Nakai et al. 2004

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 It was reported that pitting;
(i) reduced the load corresponding to yield stress;
(ii) reduced load, corresponding to ultimate tensile strength, even stronger than yield
stress;
(iii) markedly reduced total elongation to fracture;
b) Tensile strength vs. thickness loss (adapted from Matsushita et al. 2002)
Considered thickness loss due to pitting
True fracture surface can be approximated as the minimum cross sectional area

Fig b. true strength is same for uniform and non-uniform thickness (applicable to small
specimens and not for wide sections) loss thus the ultimate load capacity can be estimated
based on true fracture surface or minimum cross sectional area.

c) Total elongation vs thickness loss adapted from Matsushita et al. 2002)

uniform thickness loss doesnt cause reduction
of total elongation
Increase in DOP renders the plate to behave as
a uniformly corroded plate.

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 [11] Strength and deformability of corroded steel plates under quasi-static
tensile load
M Ahmmad and Y. Sumi, 2010
Introduction
First, determination of true stress-strain relationship for use in FEA for determination of
ultimate strength and deformability of pitted and uniformly corroded plates.
Measurement of true stress-strain relationship

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 Various methods proposed by other authors
Two difficulties
i Measurement of instantaneous area of
minimum cross section after necking
(cushion shape-like deformed zone)
ii Measurement of a/R for estimation of
correction factor

Using a vision sensor to take deformation dimensions for true strain measurements, true
stress was determined by applying correction factors defined by Ostsemin, 1992.
The true stress-strain relationship established using these correction factors was used
during numerical analysis stage
Numerical analysis (LS-DYNA)
A0
Fracture strain is defined as; f =ln ( )
Af ;
Af
projected fracture surface area

measured after experiment

Pitting corrosion modelling

Damage,

Ao A p
D m= Ap
Ao ; smallest cross sectional area due to surface pits

ep
Rd = e eo
Deformability reduction factor e o ; p pitted and intact plate total

elongation
up
R u= up uo
Ultimate strength reduction factor, uo ; pitted and intact plate

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 { }
P maxZ avg
R p=
T
Z avg
Surface roughness parameters, ; average thickness reduction
Zavg
Rs =Dm
T

Rp, is the relative difference between the depth

of the deepest pit, Pmax, and the average
corrosion diminution, zavg.
Rs is the relative difference between the
average thickness at the section of the
minimum cross-sectional area and the average corrosion
diminution, zavg.

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 [12] Topographic Characterization of Corroded Steel Surface
Johnson Garzn, Derfrey A. Duque, Carlos H. Lpez and July A. Galeano, 2008
Introduction
Corroded surface is reconstructed with the technique of laser triangulation and the various
parameters for characterizing surface topography evaluated in the interface Matlab
Experimentation
Steel plates immersed in a chemical solution to enhance corrosion.
Data collection using laser triangulation system (scanner).
Amplitude parameters
(i) Arithmetic mean Deviations at the
upper side of the Mean plane
deviation, Sa mean plane

Value obtained
0.1632 mm
Refers to
fluctuation of
the points on
the surface Deviations at the
lower side of the
about the mean mean plane

plane
(ii) Root-mean-square deviation, Sq
Measured value 0.2083

Relates to the presence of extreme points

(iii) Skewness of topography, Ssk compares the topography height distribution of
top and bottom surface about the mean plane
Spatial parameters
(i) Texture aspect ratio of the surface, Str
A measure of surface ruggedness
Other parameters measured
Area and volume characterizing parameters

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