Effect of Corrosion Products and Deposits on the Damage Tolerance of TSA-Coated Steel in Artificial Seawater

The corrosion module of COMSOL Multiphysics 5.6 (R) software was employed to simulate the influence of the corrosion products and calcareous deposits on the damage tolerance of a Thermally Sprayed Aluminium coating (TSA) in a simulated marine immersion environment. The capacity of TSA to polarise the steel was evaluated by modelling 5%, 50%, and 90% of the sample uncoated's area (i.e., substrate exposed). Additionally, the consumption of the sacrificial coating was simulated by Arbitrary Lagrangian-Eulerian (ALE) for the geometry of the experimental system. The parameters used in the model were obtained from polarisation curves and Electrochemical Impedance Spectroscopy (EIS) available in the literature. The results are in good agreement with measurements of Open Circuit Potential (OCP) and Corrosion Rate (CR) from experiments reported in previous studies. The model predicted the sacrificial protection offered by TSA as a function of the exposed steel surfaces, indicating the ability of TSA coating to polarise steel even with up to 90% damage. Furthermore, a 90-70% reduction in the corrosion rate of TSA was calculated with the simultaneous influence of corrosion products and deposits formed after 20 days of exposure to artificial seawater at room temperature.