CN112461734A - Design method for accelerated corrosion test - Google Patents
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Abstract
The present specification provides a design method for accelerated corrosion testing. The method specifically comprises the following steps: acquiring and determining a corrosion environment cumulative spectrum corresponding to a preset time unit according to corrosion environment data of an application environment; determining an indoor accelerated corrosion test spectrum according to the corrosion environment accumulated spectrum; converting the corrosion environment cumulative spectrum into a first corrosion equivalent in a preset standard state; converting the indoor accelerated corrosion test spectrum into a second corrosion equivalent in a preset standard state; comparing the first corrosion equivalent with the second corrosion equivalent to determine an equivalent acceleration relation of the indoor accelerated corrosion test relative to a cumulative spectrum of a corrosive environment; and determining the cycle times of the indoor accelerated corrosion test spectrum according to the preset action duration of the application environment and the equivalent acceleration relation. The method is beneficial to carrying out accelerated test on the material, and has the remarkable advantages of high efficiency, low cost and the like.
Description
Technical Field
One or more embodiments of the present disclosure relate to the field of detection technologies, and in particular, to a design method for an accelerated corrosion test.
Background
With the deepening of international interaction, whether equipment products can adapt to the natural environment of a global typical climate area or not and maintain higher environmental adaptability and service life indexes of multi-region use become key factors whether products can quickly seize the international market with high occupancy or not. In particular to industrial equipment such as marine machinery, aerospace, ships and the like, which are used in marine environment, the requirements on corrosion resistance and seaworthiness of component materials of the equipment are higher and higher.
In order to research the influence of the real natural environment history experienced during the whole calendar life device on the corrosion resistance of equipment component materials, currently, equipment service environment simulation tests or natural environment putting tests are mostly carried out. Although the simulation equipment has a real use environment effect, the design life of the equipment is long, for example, the design life can reach more than 20 years, so that the test period is very long, a special test site of a target region needs to be arranged and distributed, the method is difficult to realize in terms of time, expenditure and technical conditions and has huge cost, and the method can not meet the development trend of equipment development and rapid updating.
Disclosure of Invention
In view of the above, an object of one or more embodiments of the present disclosure is to provide a design method for accelerated corrosion test, so as to solve the technical problems in the prior art that the corrosion test of a component material is long in period and expensive, and it is difficult to meet the equipment development speed.
In view of the above, one or more embodiments of the present disclosure provide a design method for accelerated corrosion testing, including:
acquiring and determining a corrosion environment cumulative spectrum corresponding to a preset time unit according to corrosion environment data of an application environment;
determining an indoor accelerated corrosion test spectrum according to the corrosion environment accumulated spectrum;
converting the corrosion environment cumulative spectrum into a first corrosion equivalent in a preset standard state;
converting the indoor accelerated corrosion test spectrum into a second corrosion equivalent in a preset standard state;
comparing the first corrosion equivalent with the second corrosion equivalent to determine an equivalent acceleration relation of the indoor accelerated corrosion test relative to a cumulative spectrum of a corrosive environment;
and determining the cycle times of the indoor accelerated corrosion test spectrum according to the preset action duration of the application environment and the equivalent acceleration relation.
Further, the corrosive environment cumulative spectrum comprises a corrosive environment factor and a duration; the indoor accelerated corrosion test spectrum comprises test conditions and test time; the test conditions are matched with the corrosive environment factors; the trial time and the duration are matched.
Further, the method also comprises the following steps:
acquiring corrosion environment factors and atmospheric monitoring data corresponding to the application environment;
and processing the atmospheric monitoring data according to the corrosive environment factors to obtain the corrosive environment data.
Further, the method also comprises the following steps:
obtaining corrosion data of a material to be tested placed in the application environment and corresponding atmospheric environment data; wherein the atmospheric environmental data comprises a plurality of environmental factors;
and screening the plurality of environmental factors by a preset feature selection method according to the corrosion data and the atmospheric environmental data to determine the corrosion environmental factors.
Further, the determining step of screening the plurality of environmental factors according to the corrosion data and the atmospheric environmental data by a preset feature selection method to determine the corrosion environmental factors specifically includes:
preprocessing the atmospheric environment data to obtain preprocessed data;
taking the corrosion data as a reference sequence, taking each environmental factor in the preprocessed data as a comparison sequence, and calculating grey correlation degree;
and determining the corrosive environment factors according to the grey correlation degree and preset screening conditions.
Further, the determining step of screening the plurality of environmental factors according to the corrosion data and the atmospheric environmental data by a preset feature selection method to determine the corrosion environmental factors specifically includes:
preprocessing the atmospheric environment data to obtain preprocessed data;
performing principal component analysis and establishing a logistic regression model according to the corrosion data and the preprocessing data;
obtaining a regression equation comprising a plurality of environmental factors by using an inverse transformation method according to the principal component analysis result and the logistic regression model;
and determining the corrosion environment factors according to the coefficient absolute values of the plurality of environment factors in the regression equation and preset screening conditions.
Further, the cumulative spectrum of corrosive environment includes a plurality of corrosion states and their durations;
the step of converting the corrosion environment cumulative spectrum into a first corrosion equivalent in a preset standard state specifically includes:
obtaining a first corrosion current density of a material to be tested in a preset standard state;
obtaining a second corrosion current density of the material to be tested in a test state;
determining an environment equivalent conversion coefficient of the material under a test state relative to a preset standard state according to the first corrosion current density and the second corrosion circuit density;
matching each corrosion state with the test state, and determining an environment equivalent conversion coefficient corresponding to each corrosion state;
and counting to obtain a first corrosion equivalent according to the environment equivalent conversion coefficient and the duration of each corrosion state.
Further, the indoor accelerated corrosion test spectrum comprises a plurality of test conditions;
the step of converting the indoor accelerated corrosion test spectrum into a second corrosion equivalent in a preset standard state specifically includes:
obtaining a first corrosion current density of a material to be tested in a preset standard state;
obtaining a third corrosion current density of the material to be tested under the test condition;
determining a test equivalent conversion factor of the material under test conditions relative to a preset standard state according to the first corrosion current density and the third corrosion current density;
matching each test condition with the test condition, and determining a test equivalent conversion coefficient corresponding to each test condition;
and counting the second corrosion equivalent according to the test equivalent conversion coefficient.
Further, determining the total duration of the accelerated corrosion test according to the cycle times and the single cycle time of the indoor accelerated corrosion test spectrum; adjusting the indoor accelerated corrosion test spectrum and re-determining the cycle number according to the total duration and the corrosion characteristics of the material; the corrosion characteristics are determined from corrosion data of the material to be tested placed in an application environment.
Further, the sample mode of the indoor accelerated corrosion test spectrum is selected from one of periodic infiltration and circulating salt fog.
As can be seen from the above description, one or more embodiments of the present disclosure provide a method for designing an accelerated corrosion test, which obtains and determines a cumulative spectrum of a corrosion environment corresponding to a preset time unit according to corrosion environment data of an application environment; determining an indoor accelerated corrosion test spectrum according to the corrosion environment accumulated spectrum; converting the corrosion environment cumulative spectrum into a first corrosion equivalent in a preset standard state; converting the indoor accelerated corrosion test spectrum into a second corrosion equivalent in a preset standard state; comparing the first corrosion equivalent with the second corrosion equivalent to determine an equivalent acceleration relation of the indoor accelerated corrosion test relative to a cumulative spectrum of a corrosive environment; and determining the cycle times of the indoor accelerated corrosion test spectrum according to the preset action duration of the application environment and the equivalent acceleration relation. According to the technical scheme, the indoor accelerated corrosion test spectrum is determined through the corrosion environment accumulation spectrum, equivalent conversion of the corrosion environment accumulation spectrum and the indoor accelerated corrosion test spectrum is achieved by utilizing the preset standard state, so that the single cycle times of the indoor accelerated corrosion test spectrum can be conveniently determined according to the preset acting duration, the design of an accelerated test is achieved, the follow-up accelerated test on materials is facilitated, and the method has the remarkable advantages of high efficiency, low cost and the like.
Drawings
In order to more clearly illustrate one or more embodiments or prior art solutions of the present specification, the drawings that are needed in the description of the embodiments or prior art will be briefly described below, and it is obvious that the drawings in the following description are only one or more embodiments of the present specification, and that other drawings may be obtained by those skilled in the art without inventive effort from these drawings.
FIG. 1 is a schematic flow diagram of a design method for accelerated corrosion testing provided in one or more embodiments of the present disclosure;
FIG. 2 is a schematic flow diagram of a method for obtaining data of a corrosive environment according to one or more embodiments of the present disclosure;
FIG. 3 is a schematic flow diagram of a method for determining a corrosive environment factor provided in one or more embodiments of the present disclosure;
FIG. 4 is a schematic flow diagram of a method for determining a corrosive environment factor using a gray correlation provided in one or more embodiments of the present disclosure;
FIG. 5 is a schematic flow diagram of a method of determining a first corrosion equivalent as provided in one or more embodiments of the present disclosure.
Detailed Description
For the purpose of promoting a better understanding of the objects, aspects and advantages of the present disclosure, reference is made to the following detailed description taken in conjunction with the accompanying drawings.
It is to be noted that unless otherwise defined, technical or scientific terms used in one or more embodiments of the present specification should have the ordinary meaning as understood by those of ordinary skill in the art to which this disclosure belongs. The use of "first," "second," and similar terms in one or more embodiments of the specification is not intended to indicate any order, quantity, or importance, but rather is used to distinguish one element from another. The word "comprising" or "comprises", and the like, means that the element or item or method preceding the word covers the element or item or step listed after the word and its equivalents, but does not exclude other elements or items or steps.
At present, after part of equipment (such as a carrier-based aircraft) is delivered to a customer for use, the equipment is in a storage non-working or parking state for most of time, and the ground or ship surface parking time generally accounts for more than 90% of the whole service life, so that the ground or ship surface storage atmospheric environment becomes a main factor causing corrosion damage to component materials. As the service environment of coastal areas or island reefs and other areas is a combined damp-heat and chemical corrosion environment, the metal materials of the equipment inevitably have corrosion problems such as uniform corrosion, local corrosion, stress action corrosion and the like in the long-term storage process.
In the service life of most equipment products, the action process of various environmental factors on structural parts is long, and the characteristics of spectrum change, different duration and the like are achieved. If the environment spectrum synchronous with the calendar life is compiled to describe all the change courses of the environment factors, the laboratory manual simulation reproducing means has great difficulty, and the research significance is not great even if the environment spectrum is equal to the calendar life. Moreover, the method is difficult to realize in terms of time, cost and technical conditions and has huge cost, and the development trend of equipment development and rapid updating cannot be met.
In view of this, one or more embodiments of the present disclosure provide a design method for accelerated corrosion testing. As shown in fig. 1, the design method includes:
step 101: and acquiring and determining a corrosion environment cumulative spectrum corresponding to a preset time unit according to the corrosion environment data of the application environment.
As will be appreciated by those skilled in the art, natural atmospheric environmental factors generally include both climatic environmental factors and chemical corrosion factors. Wherein the climate environmental factors generally include temperature, humidity, precipitation, wind and fogClimatic phenomena, solar radiation, solid sediments, etc. The chemical environmental factors affecting the corrosion of structural materials mainly include SO2、
NOxAcid rain, salt fog, Cl-And the like.
Further, there are differences in natural atmospheric environmental factors in different geographical locations, such as islands in the sea, deserts, and plateau areas. Different ones of the aforementioned natural atmospheric environmental factors (e.g., wind, air temperature) also have different degrees of impact on material corrosion for a given geographic location.
Thus, in one or more embodiments of the present description, the corrosion environment data refers to environmental data that has an effect on corrosion of a material. Illustratively, the corrosive environment data includes temperature data, relative humidity data, and the like. Further, the corrosion environment data includes not only environmental factors but also intensity, duration, frequency of occurrence, and the like of the environmental factors.
Alternatively, the corrosive environment data may include acid rain, salt spray, and the like, depending on the particular material to be tested and the environment of use. Among them, sulfur oxides and acid rain are key factors causing atmospheric corrosivity in industrial areas, and salt spray is an important environmental factor which must be considered in coastal or island and reef areas.
The corrosion environment data is determined by a processing method such as statistics and conversion based on a large amount of atmospheric detection data of the application environment and based on the corrosion environment factors.
Optionally, the preset time unit is selected from month, quarter, half year, etc.
Illustratively, for a four season clear region, the predetermined time unit is year and the cumulative spectrum of corrosive environment is cumulative annual spectrum. Accordingly, the time duration of the corrosive environment data is at least one year. In this way, it can be ensured that the cumulative spectrum of the corrosive environment can sufficiently reflect the true corrosive environment. It should be appreciated that to improve the representativeness of the cumulative spectrum of the corrosive environment, the corrosive environment data includes years of data, such as three years, four years.
Illustratively, for regions without seasonal differentiation, the preset time unit is month, quarter, and the like. And will not be described in detail herein.
It should be noted that the cumulative spectrum of the corrosive environment is based on the data of the corrosive environment, and counts the intensity, action time, action times, and combination thereof of each corrosive environment factor, so as to quantitatively describe the action process of the corrosive environment to which the equipment is subjected in the life cycle process.
Illustratively, changes in air temperature can affect the reaction rate of corrosion and the residence time of the water film on the metal surface. Under high temperature and high humidity conditions, the corrosion rate of metal materials is remarkably increased along with the increase of temperature. When the environmental temperature is lower than 0 ℃, the influence on the corrosion of structural components is small, so when a corrosion environment accumulation spectrum is compiled, only the condition that the temperature is higher than 0 ℃ is generally considered. Therefore, the temperature range of 5-35 ℃ is divided into 7 temperature levels according to 5 ℃ equally, the temperature is taken as a reference index, and the action time and times of other corrosion environment factors such as humidity, precipitation, condensation, salt fog and the like and the action time corresponding to each temperature section with the relative humidity of more than 70% and the temperature of more than 20 ℃ are counted.
Illustratively, metal material corrosion has a critical relative humidity below which little corrosion of the metal material occurs; the rate of corrosion of the metal increases rapidly when the critical humidity is reached and exceeded. The relative humidity values of different metals or the same metal material in different environments are different. For common metal materials such as aluminum alloy, alloy steel and the like, it is currently generally considered that the critical value of the relative humidity is 70%, namely, the relative humidity is lower than 70%, and the material can be considered as dry air. Therefore, exposure times with relative humidities greater than 70% are generally counted.
Exemplary, the main factor responsible for industrial pollution and atmospheric corrosivity of marine environments is SO2And Cl－And the content of atmospheric components. In the early service period of the equipment, the corrosion influence on structural materials is large. Therefore, it is usually necessary to count the average content of the two corrosion media in a predetermined time unit.
It should be noted that compiling the corrosion environment accumulation spectrum is the key to the work of corrosion design and control, structural life assessment and durability analysis in the corrosion environment, and the like.
Step 102: and determining an indoor accelerated corrosion test spectrum according to the corrosion environment accumulated spectrum.
Optionally, the sample mode of the indoor accelerated corrosion test spectrum is selected from one of periodic immersion and circulating salt fog.
The circulating salt spray can get rid of the limitation of the traditional solution infiltration corrosion method, and is convenient to realize the cooperative application with other types of environmental stress.
The larger acceleration factor of the indoor accelerated corrosion test is usually required to be set for predicting the corrosion life of equipment product materials, but the larger the acceleration factor is, the poorer the correlation between the indoor test result and the outfield storage result is. In order to ensure that the indoor and outdoor corrosion test methods have better correlation, the accelerated corrosion test generally follows the following design principle: the electrochemical mechanisms of corrosion failure of indoor and outdoor test materials are ensured to be consistent; the process and the characteristics of the environment circulation effect are consistent; the corrosion dynamics rules are consistent; the corrosion products have the same components and the growth sequence is consistent; the acceleration multiplying power is high, and the initial acceleration multiplying power value is as large as possible; the result reproducibility of the repeated repeatability comparison test is good.
It should be noted that, the indoor accelerated corrosion test spectrum can reflect the corrosion environment factors and the duration characteristics reflected by the corrosion environment cumulative spectrum, so as to simulate the corrosion environment cumulative spectrum with high efficiency.
As an alternative embodiment, the corrosive environment cumulative spectrum includes a corrosive environment factor and duration; the indoor accelerated corrosion test spectrum comprises test conditions and test time; the test conditions are matched with the corrosive environment factors; the trial time and the duration are matched.
It should be noted that, the matching between the test conditions and the corrosive environment factors means that the corrosive environment factors are all reflected in the test conditions. The matching of the trial time and the duration includes, but is not limited to, matching of a trial time law and a duration law.
Illustratively, the corrosive environmental factor comprises temperature, whereby the test conditions comprise temperature control conditions; the corrosive environmental factor comprises salt spray, whereby the test conditions comprise salt spray conditions.
Step 103: and converting the corrosion environment cumulative spectrum into a first corrosion equivalent of a preset standard state.
It should be noted that, according to the test requirement, a person skilled in the art may set the preset standard state, which is not specifically limited herein.
For example, the predetermined standard state may be 40 ℃ and 90% relative humidity.
Illustratively, the cumulative spectrum of the corrosive environment comprises 20 ℃ and 70% of relative humidity, and the duration is 80h, which can be converted into the duration of the preset standard state. And converting the cumulative spectrum of the corrosive environment into the duration of a preset standard state to obtain a first corrosion equivalent.
Step 104: and converting the indoor accelerated corrosion test spectrum into a second corrosion equivalent in a preset standard state.
Illustratively, the indoor accelerated corrosion test spectrum comprises 5% NaCl, and if the test time is 1h, the indoor accelerated corrosion test spectrum can be converted into 3.168h under a preset standard state.
Step 105: and comparing the first corrosion equivalent with the second corrosion equivalent to determine the equivalent acceleration relation of the indoor accelerated corrosion test relative to the cumulative spectrum of the corrosive environment.
Step 106: and determining the cycle times of the indoor accelerated corrosion test spectrum according to the preset action duration of the application environment and the equivalent acceleration relation.
It should be noted that the preset action duration of the application environment is the designed service life of the equipment in service. The service place is equivalent to the application environment, such as islands, coastal ports and the like. The design life is equivalent to the preset action duration.
It will be appreciated that typically the predetermined length of action is much greater than the predetermined time unit of the cumulative spectrum of the corrosive environment, for example the predetermined time unit is a year, and the predetermined length of action may be 20 years.
It should be noted that if the second corrosion equivalent is determined according to a test time of 1h, the single cycle time of the indoor accelerated corrosion test spectrum should be considered when determining the cycle number of the indoor accelerated corrosion test spectrum, and the specific scheme is not described herein again.
According to the technical scheme, the indoor accelerated corrosion test spectrum is determined through the corrosion environment accumulation spectrum, equivalent conversion of the corrosion environment accumulation spectrum and the indoor accelerated corrosion test spectrum is achieved by utilizing the preset standard state, so that the single cycle times of the indoor accelerated corrosion test spectrum can be conveniently determined according to the preset acting duration, the design of an accelerated test is achieved, follow-up accelerated test on materials can be facilitated, and the method has the remarkable advantages of high efficiency, low cost and the like.
By adopting the accelerated corrosion test method, the corrosion effect which is the same as that of the ground storage of the equipment member for a plurality of years can be obtained in a short time, the degradation rule of the corrosion damage of the equipment key metal material is mastered, and basic data and technical support are provided for the service life evaluation of the equipment key member in engineering.
Referring to FIG. 2, one or more embodiments of the present disclosure further include a step of obtaining data of the corrosive environment. Specifically, the method comprises the following steps:
step 201: and acquiring corrosion environmental factors and atmospheric monitoring data corresponding to the application environment.
It should be noted that, if the corrosive environment factor of the material to be tested in the application environment is clear, such as can be obtained from literature, it can be directly obtained. Of course, if the corrosive environment factor corresponding to the material to be tested in the application environment cannot be obtained from the data, the corrosive environment factor can be determined by the previous screening test, and this will be described in detail later.
Illustratively, the corrosive environmental factors include temperature, relative humidity, rainfall, and the like.
It should be understood that the atmospheric monitoring data may be obtained from local gas phase departments, or may be monitored by laboratory personnel. The atmospheric monitoring data comprise average air temperature, average relative humidity, sunshine hours, total radiant quantity, salt spray settlement rate, chloride ion concentration, rainfall, wind speed, water-soluble dust and the like.
It should be noted that the time range of the atmosphere monitoring data at least covers the preset time unit.
Illustratively, the preset time unit is a year, and the atmosphere monitoring data includes at least one year of monitoring data.
Step 202: and processing the atmospheric monitoring data according to the corrosive environment factors to obtain the corrosive environment data.
It should be noted that the atmospheric monitoring data includes a plurality of environmental factors, which are much greater than the corrosive environmental factors.
The plurality of environmental factors of the atmospheric monitoring data are screened by utilizing the corrosive environmental factors, so that the atmospheric monitoring data can be effectively simplified, the environmental action mechanism is not changed, and the subsequent and convenient corrosion or aging effect of the environmental factors on the equipment structure can be conveniently reproduced.
In the case where the corrosion factor is not available from the literature, one or more embodiments of the present specification also provide a method for determining a corrosive environmental factor. Referring to fig. 3, the method specifically includes:
step 301: obtaining corrosion data of a material to be tested placed in the application environment and corresponding atmospheric environment data; wherein the atmospheric environmental data comprises a plurality of environmental factors.
It should be noted that the corrosion data includes corrosion rate, pitting depth, and the like.
For example, the corrosion rate of a carbon steel coupon (Q235) within 1 was 291.84 μm/a (where a represents year).
Optionally, according to the failure mechanism and corrosion characteristics of the material to be tested in the application environment, the atmospheric environment data can be preliminarily selected to remove atmospheric environment factors completely unrelated to the corrosion of the material to be tested, such as water-insoluble dust.
Step 302: and screening the plurality of environmental factors by a preset feature selection method according to the corrosion data and the atmospheric environmental data to determine the corrosion environmental factors.
Alternatively, the preset feature selection method may be an optimal subset method, a stepwise regression method, or the like. The detailed description of the optimal subset method and the stepwise regression method is omitted.
By the scheme, the corrosion environment factors which play a main role in the corrosion of the material to be tested in the application environment can be obtained, and the accurate corrosion environment accumulation spectrum is obtained.
To facilitate a thorough understanding of the method of determining the corrosive environmental factors, one alternative embodiment is provided in the present specification.
Specifically, referring to fig. 4, the step of screening the plurality of environmental factors according to the corrosion data and the atmospheric environmental data by a preset feature selection method to determine the corrosion environmental factors includes:
step 401: and preprocessing the atmospheric environment data to obtain preprocessed data.
It should be appreciated that since each environmental factor is different in size and unit, the environmental factor data needs to be preprocessed before the feature selection method is utilized.
Optionally, the pre-processing method comprises one or more of initialization, minimum/maximum, averaging and interval.
Step 402: and taking the corrosion data as a reference sequence, taking each environmental factor in the preprocessed data as a comparison sequence, and calculating the grey correlation degree.
Here, it should be noted that the grey correlation theory can establish the correlation between the corrosion process of the service of the material and the change process of the main environmental factors. The grey correlation analysis calculates the correlation degree by the following main steps: determining a comparison array and a reference array; calculating a correlation coefficient; and (5) calculating the degree of association.
The gray correlation expression and calculation process is generally as follows:
suppose X0(k) Is a reference series of the amount of corrosion of the material to be tested, Xi(k) Defining X for a comparison series of environmental factors0(k) And Xi(k) Correlation coefficient xi at time k0i(k) Comprises the following steps:
if Δi(k)＝|X0′(k)-Xi' (k) |, then:
in the formula: rho is a resolution coefficient, rho is more than 0 and less than 1, and the specific value of rho can be determined according to specific conditions and is generally 0.5.
Δi(k) Is the k-th time, X0And XiThe absolute difference of (a);
Therefore, X can be obtained from this formula (2)i(k) And corresponding X0(k) Correlation coefficient between:
ξi＝{ξi(k)|k＝1,2,…n} (3)
defining the gray correlation of the comparison array to the reference array as gamma (X)0,Xi) Then the degree of association can be expressed as:
step 403: and determining the corrosive environment factors according to the grey correlation degree and preset screening conditions.
The correlation between the reference sequence and the comparison sequence is γi(i is 1,2, … m), the relation of the associated sequence is formed, and the gray associated sequence can be obtained by arranging from large to small. From which a certain sequence with the greatest relevance and highest degree of membership can be determined. That is, the sequence with the maximum γ has the maximum degree of association, and the sequence with the minimum γ has the minimum degree of association.
It should be noted that the preset screening condition includes at least one of the setting of γ and the number of corrosive environment factors.
Illustratively, in general, when γ > 0.6, the sequence has a good correlation. The preset screening condition may be to select the first five environmental factors with gamma > 0.6 as the corrosive environmental factors.
As an alternative embodiment, the determining step of screening the plurality of environmental factors according to the corrosion data and the atmospheric environmental data by a preset feature selection method to determine the corrosion environmental factors specifically includes:
and preprocessing the atmospheric environment data to obtain preprocessed data.
It should be noted that the preprocessing method in this step is similar to step 401, and is not described here in detail.
And performing principal component analysis and establishing a logistic regression model according to the corrosion data and the pretreatment data.
Here, Principal Component Analysis (PCA) is a technique of simplifying a data set. The data is transformed into a new coordinate system by a linear transformation such that the first large variance of any data projection is at the first coordinate (called the first principal component), the second large variance is at the second coordinate (the second principal component), and so on.
Here, the detailed description of the principal component analysis is omitted.
The principal component analysis result can obtain a plurality of principal components, for example, a first principal component, a second principal component, and the like, and a logistic regression model can be established using the plurality of principal components.
Obtaining a regression equation comprising a plurality of environmental factors by using an inverse transformation method according to the principal component analysis result and the logistic regression model;
it should be noted that the inverse transformation method is a commonly used calculation method in the art, and is not described in detail here.
And determining the corrosion environment factors according to the coefficient absolute values of the plurality of environment factors in the regression equation and preset screening conditions.
Here, the preset screening conditions include conditions that the absolute value of the coefficient should satisfy, the number of corrosive environment factors, and the like.
By combining principal component analysis with a logistic regression model, a plurality of environmental factors can be screened, and the environmental factors can be selected by less calculation to obtain an optimal corrosive environment factor set.
In order to realize the accelerated simulation of the cumulative spectrum of the corrosive environment, the corrosion equivalent of the cumulative spectrum of the corrosive environment and the indoor accelerated corrosion test spectrum also needs to be determined. Here, the raw materials for determining the corrosion equivalent in this specification will be briefly described.
Under the environment conditions of storage and duty, the metal material can generate electrochemical corrosion effect, and serious corrosion and corrosion occur, so that the mechanical property is reduced.
The corrosion kinetics of metallic materials follow a power function law:
D＝Atn (5)
in the formula: d is the depth of the etch or the loss of etch quality; t is the etching time; a is a corrosion rate constant, generally the 1 st year corrosion rate of the material, and is mainly related to the corrosivity grade of environmental factors; n is a power index, and the smaller the value, the better the corrosion resistance of the metal material is.
The correlation of the indoor and outdoor corrosion tests refers to the equivalent comparison of two groups of corrosion results with the same corrosion mechanism but different action processes. The equivalent corrosion acceleration relation is the comparison relation between the action time of the accelerated corrosion spectrum and the corrosion action time of the outfield natural environment on the premise of equal corrosion. Because the metal material mainly generates electrochemical corrosion reaction in atmospheric environment, in the electrochemical corrosion reaction process, the charge transfer and the reaction substance have close equivalent relation, and obey Faraday's law. Thus, the corrosion current I can be usedcAnd compiling an atmospheric environment accelerated corrosion test spectrum for the measurement parameters. For a given metal material, although the change of external environmental factors along with time is in a spectrum-like change rule, the corrosion of the material under a specific environment is strong and weak, and the corrosion current density IcAs well as over time. However, during the exposure time t, the corrosion charge Q of the metal can be expressed in the form of an integral:
in the formula: f is a Faraday constant; i iscIs the current in different environments; t is the environmental exposure time.
If the current under in-situ ambient conditions is I for a given metallic material and combination thereofcThe exposure time is t, and the corrosion amount is Q; while it accelerates the corrosion testThe corrosion current under the condition of spectrum inspection is I'cThe test time is t ', the corrosion quantity is Q', and the following is shown according to the formula (6):
according to the criterion of equal corrosion amount Q ═ Q', the following results are obtained:
Ict＝I′ct′ (8)
this gives:
introducing a conversion coefficient, namely an acceleration factor:
then there are:
t′＝αt (11)
the formula (11) gives the action time relationship corresponding to the equal corrosion amount in the two environments, and is the basis for establishing the equivalent relationship between the action time of the acceleration test spectrum and the atmospheric environment spectrum by using an equivalent conversion method.
Using the equivalent folding algorithm, based on faraday's law, it is believed that corrosion failure of metallic materials is mainly caused by electrochemical corrosion. In the electrochemical reaction process, an equivalent relation exists between the transfer of the charge quantity and the variable quantity of the reactant, so that the corrosion electric quantity under the accelerated environment spectrum is equal to the corrosion electric quantity in the application environment, and the equivalent relation between the accelerated corrosion test spectrum and the corrosion environment accumulation spectrum is further determined.
The corrosion polarization curve can be used as an important means for representing the equivalent corrosion principle, can reflect the change of the cathode and anode processes in the corrosion process, represents the corrosion mechanism, and can also measure the corrosion current. The determination and comparison of the corrosion polarization curves can play an important role in determining the acceleration factor associated with corrosion in the chamber. On one hand, the shapes of polarization curves measured in the indoor and outdoor corrosion test processes are basically consistent, and the mechanisms of the indoor and outdoor corrosion processes are basically consistent; on the other hand, the corrosion acceleration ratio can be calculated from the measured corrosion current density on the basis of the principle of the equivalent acceleration relationship.
In one or more embodiments of the present description, a first corrosion equivalent determination scheme is provided.
In particular, the corrosive environment cumulative spectrum comprises a plurality of corrosion states and their durations;
referring to fig. 5, the step of converting the cumulative spectrum of the corrosive environment into a first corrosion equivalent of a predetermined standard state includes:
step 501: and acquiring a first corrosion current density of the material to be tested in a preset standard state.
Here, the preset standard state is as described above and will not be described in detail.
Step 502: and acquiring a second corrosion current density of the material to be tested in the test state.
It should be noted that the test conditions include combinations of different temperatures and humidities. For example, a relative humidity of 70%, a temperature of 20 ℃, a relative humidity of 80%, a temperature of 35 ℃ and the like.
Step 503: and determining an environment equivalent conversion coefficient of the material under the test state relative to a preset standard state according to the first corrosion current density and the second corrosion circuit density. Illustratively, the equivalent reduction factor is shown in table 1. Wherein the preset standard state corresponds to the relative humidity of 90% and the temperature of 40 ℃.
TABLE 1 conversion factor between test state and preset standard state
Step 504: and matching each corrosion state with the test state, and determining the environment equivalent conversion coefficient corresponding to each corrosion state.
It should be noted that the cumulative spectrum of the corrosion environment includes a plurality of corrosion states, and different corrosion states correspond to different conversion factors, so that each corrosion state needs to be matched with a test state.
Step 505: and counting to obtain a first corrosion equivalent according to the environment equivalent conversion coefficient and the duration of each corrosion state.
According to the technical scheme, equivalent conversion of the corrosion environment accumulation spectrum is realized by utilizing a preset standard state based on Faraday's law, and the accuracy and repeatability of the equivalent conversion can be effectively guaranteed.
In one or more embodiments of the present disclosure, the indoor accelerated corrosion test profile comprises a plurality of test conditions;
the step of converting the indoor accelerated corrosion test spectrum into a second corrosion equivalent in a preset standard state specifically includes:
and acquiring a first corrosion current density of the material to be tested in a preset standard state.
Here, the obtained first etching current density is the same as the step 501, and is not described again.
And acquiring a third corrosion current density of the material to be tested under the test condition.
It should be noted that the test conditions include water, NaCl solutions with different concentrations, acid solutions, and the like.
It should be noted that, an atmospheric corrosion detector (ACM), a self-made electrode and a humid and hot environment chamber are used to measure the corrosion current density (40 ℃, RH 90%) of the metal material to be tested at a test temperature of 40 ℃ and a relative humidity of 90% (a preset standard state, such as standard humid air), and to measure the corrosion current density of the material to be tested under the test conditions.
Determining a trial equivalent reduction factor of the material under test conditions relative to a preset standard state based on the first corrosion current density and the third corrosion current density.
The equivalent conversion coefficient of the material to be tested under the test conditions relative to the preset standard conditions is obtained by taking the temperature of 40 ℃ and the relative humidity of 90% as the preset standard conditions of the accelerated corrosion test, which is detailed in table 2.
TABLE 2 conversion factor of different test conditions to aqueous medium
And matching each test condition with the test condition to determine the equivalent conversion coefficient corresponding to each test condition.
It should be noted that, if the test conditions are different, the equivalent conversion factors are different.
Optionally, to facilitate simplified processing, the test conditions have the same temperature as the predetermined standard conditions.
And counting the second corrosion equivalent according to the test equivalent conversion coefficient.
According to the technical scheme, equivalent conversion of the accelerated corrosion test spectrum is realized by utilizing a preset standard state based on Faraday's law, and the accuracy and repeatability of the equivalent conversion can be effectively guaranteed.
Further, when the test condition is not matched with the test condition, calculating a corresponding test equivalent conversion coefficient by using an interpolation method according to the test condition and the test condition.
One or more embodiments of the present description further include: determining the total duration of the accelerated corrosion test according to the cycle times and the single cycle time; adjusting the indoor accelerated corrosion test spectrum and re-determining the cycle number according to the total duration and the corrosion characteristics of the material; the corrosion characteristics are determined according to corrosion data of the material to be tested placed in an application environment.
Here, the corrosion characteristics include, but are not limited to, corrosion rate.
Here, the indoor accelerated corrosion test spectrum is adjusted, specifically, parameters such as salt solution concentration, pH value, and temperature are adjusted, so as to adjust the acceleration multiple.
Through such technical scheme, can realize adjusting the total duration of indoor accelerated corrosion test for the scheme of accelerated corrosion test is convenient for operate the realization more.
The accelerated corrosion test spectrum design method disclosed by one or more embodiments of the specification has strong applicability and wide application field, and can be used for accelerated corrosion tests of various atmospheric natural environment types and equipment structural materials; the test spectrum has higher accelerated corrosion rate, can expose the corrosion behavior and the electrochemical corrosion mechanism of the structural material in a shorter time, and is basically consistent with the external field corrosion behavior and the failure mechanism. Through an indoor accelerated corrosion test, the corrosion resistance of equipment metal and alloy materials and a plating process can be rapidly verified and screened, and the corrosion life of the equipment structural material can be rapidly verified and predicted.
Further, the method is suitable for most metals, alloys and coating materials and processes thereof which are widely used in equipment structures.
It should be noted that the above description describes certain embodiments of the present disclosure. Other embodiments are within the scope of the following claims. In some cases, the actions or steps recited in the claims may be performed in a different order than in the embodiments and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In some embodiments, multitasking and parallel processing may also be possible or may be advantageous.
The design method provided in the present specification is further explained below with a carbon steel test piece (Q235) as a material to be tested and a typical atmospheric environment (sea island) as an application environment.
The corrosion rate of Q235 is described in μm/a, as is the average corrosion rate of the test pieces for different test cycles, according to the field exposure test data of a carbon steel test piece (Q235) in a typical atmospheric environment, as exemplified in Table 3.
TABLE 3 Corrosion Rate of Q235 exposed to different cycles in a typical atmospheric environment
According to the failure mechanism and corrosion characteristics of carbon steel in a typical atmospheric environment, 7 factors influencing the corrosion process and the corrosion life are preliminarily selected for grey correlation degree analysis, and the initial values of statistical analysis according to data of every 4 months are shown in Table 4.
TABLE 4 typical atmospheric environmental main corrosion factor time data
Here, the preprocessing method employed averaging to process the data in table 4, and the results are shown in table 5.
TABLE 5 average results of the main corrosion factors in typical atmospheric environments
The grey correlation between the average corrosion rate of Q235 and the major corrosion factors of the atmospheric environment was calculated and ranked using the grey correlation calculation and analysis method described previously and the results are shown in table 6. As can be seen from table 6, the main factors (corresponding to the corrosive environment factors) affecting the Q235 corrosion process are rainfall, relative humidity, temperature, salt fog precipitation, etc., and the correlation values between them are small, and the effects on the corrosion process are relatively close. By a similar method, corrosion-affecting factors of materials such as aluminum alloys, stainless steels, and the like can be screened.
TABLE 6 Grey correlation and ranking of corrosion Rate and environmental factors in a typical atmospheric Q235 Environment
Atmospheric monitoring data of a typical atmospheric environment in 4 years are obtained (refer to table 4), and the atmospheric monitoring data are selected and simplified by using the corrosive environment factors determined by the grey correlation method to obtain the corrosive environment data.
As the climatic region is almost in a high-temperature and high-humidity climatic environment all the year round, the data statistics result shows that the time of the air temperature lower than 20 ℃ and the time of the air temperature higher than 35 ℃ occupy a small proportion of the time of one year, and the influence on equipment can be ignored. Therefore, the duration of the corrosion environment factors such as temperature, humidity and rain fog is accumulated according to the year on the corrosion environment data mainly according to two temperature intervals of 25 ℃ and 30 ℃, and the compiling results of the temperature-humidity spectrum and the rain-fog spectrum are shown in tables 7 and 8. The proportion of annual humidity less than 70% is about 27%.
TABLE 7 cumulative spectrum of atmospheric humiture and rain-fog years
TABLE 8 annual atmospheric composition of the spectra
Aiming at the atmospheric environmental characteristics of high temperature, high humidity and high salt fog of the corrosion environment cumulative spectrum (such as the atmospheric temperature and humidity, rain fog annual cumulative spectrum and atmospheric environmental annual spectrum), an indoor accelerated corrosion test spectrum can be formulated by adopting corrosion test modes such as periodic infiltration or circulating salt fog.
The corrosion acceleration adopts 5 percent of NaCl and 0.05 percent of Na2SO4+0.05％CaCl2The pH value of the mixed solution is adjusted to be 4 by using a small amount of dilute hydrochloric acid, and the solution has good typical atmospheric environment corrosion acceleration. Moist airThe action process of the environment such as condensation and dry air is simulated by adopting the baking process of the sample surface solution in the warm and humid environment, namely the sample surface solution is dried to disappear in a preset standard state with the temperature t being 40 ℃ and the relative humidity being 90%. Therefore, the indoor accelerated corrosion test spectrum can be preliminarily set, and the specific test spectrum comprises the following components:
(a) the etching solution is 5% NaCl + 0.05% Na2SO4+0.05％CaCl2The mixed solution of (1);
(b) salt spray spraying: the temperature is (40 +/-1) DEG C, the duration is 4 hours, and the salt solution sedimentation rate is 1-3 mL/(80 cm)2·h)；
(c) And (3) drying: the temperature is (60 +/-1) DEG C, the RH is less than 30 percent, and the time lasts for 4 hours;
(d) the single cycle period is 8h, and the conversion time of the dry-wet process is not more than 0.5 h.
The cumulative spectrum of the corrosive environment (refer to tables 7 and 8) was converted into the corrosion equivalent of the preset standard state. The hours of the humid air at each temperature in the annual cumulative spectrum (table 8) of the atmospheric environment are converted into the hours of the humid air at the temperature of 40 ℃ and the hours of the humid air at the relative humidity of 90% in the preset standard state according to the data in table 1, wherein ta is 1209.6 h. The condition that the effect of the rain in the external field is approximately equal to the effect of the rain in the relative humidity of 90% is processed, and then the rainfall hours in the atmospheric environment annual accumulation spectrum (table 8) are converted into the effect hours tb of the preset standard state with the temperature of 40 ℃ and the relative humidity of 90% according to the data in table 1, which is 249.1h, so that the atmospheric environment annual accumulation spectrum is equivalent to the effect time of the preset standard state as follows: t1 ta + tb 1458.7 h.
And converting the indoor accelerated corrosion test spectrum into the corrosion equivalent of a preset standard state. First is the acceleration factor of the NaCl salt solution. As can be seen from the data in Table 2, the 5% NaCl solution obtained by interpolation has an acceleration factor of about 3.168, corresponding to a conversion factor of β10.316; secondly the reduced coefficient of dilute hydrochloric acid, for dilute hydrochloric acid [ H ] at pH 4+]＝10－4mol/L, HCl concentration is 10－4And the mass concentration of the hydrochloric acid is 3.65mg/L when the concentration is mol/L. As can be seen from the data in Table 2, the reduced coefficients of hydrochloric acid at concentrations of 1 and 2mg/L to the predetermined standard state are 0.368 and 0.292. Also by interpolationThe acceleration coefficient of the obtained 3.65mg/L hydrochloric acid solution is 5.998, and the corresponding conversion coefficient beta20.167. The combined acceleration factor of the accelerated corrosion test spectrum is 9.156. Therefore, the effect of the accelerated corrosion test spectrum for 1h is equivalent to the effect of 9.156h under the preset standard state of the temperature of 40 ℃ and the relative humidity of 90%.
Equivalent conversion is carried out on the action effect of the Q235 carbon steel under the atmospheric environment spectrum and the indoor accelerated corrosion test spectrum. From the above calculation results, it is found that the equivalent acceleration relationship of the indoor accelerated corrosion test spectrum is 159.3h/a, that is, 159.3h (about 6.64d) of the indoor accelerated corrosion test spectrum corresponds to the corrosion equivalent of the external field atmospheric environment effect 1 a.
And finally, comprehensively determining the cycle number of the indoor accelerated corrosion test spectrum according to the predicted action time (for example, 20 years) of the typical atmospheric environment, the equivalent acceleration coefficient and the single cycle time.
Those of ordinary skill in the art will understand that: the discussion of any embodiment above is meant to be exemplary only, and is not intended to intimate that the scope of the disclosure, including the claims, is limited to these examples; within the spirit of the present disclosure, features from the above embodiments or from different embodiments may also be combined, steps may be implemented in any order, and there are many other variations of different aspects of one or more embodiments of the present description as described above, which are not provided in detail for the sake of brevity.
It is intended that the one or more embodiments of the present specification embrace all such alternatives, modifications and variations as fall within the broad scope of the appended claims. Therefore, any omissions, modifications, substitutions, improvements, and the like that may be made without departing from the spirit and principles of one or more embodiments of the present disclosure are intended to be included within the scope of the present disclosure.
Claims (10)
1. A design method for accelerated corrosion testing is characterized by comprising the following steps:
acquiring and determining a corrosion environment cumulative spectrum corresponding to a preset time unit according to corrosion environment data of an application environment;
determining an indoor accelerated corrosion test spectrum according to the corrosion environment accumulated spectrum;
converting the corrosion environment cumulative spectrum into a first corrosion equivalent in a preset standard state;
converting the indoor accelerated corrosion test spectrum into a second corrosion equivalent in a preset standard state;
comparing the first corrosion equivalent with the second corrosion equivalent to determine an equivalent acceleration relation of the indoor accelerated corrosion test relative to a cumulative spectrum of a corrosive environment;
and determining the cycle times of the indoor accelerated corrosion test spectrum according to the preset action duration of the application environment and the equivalent acceleration relation.
2. The design method of claim 1, wherein the corrosive environment cumulative spectrum comprises a corrosive environment factor and a duration; the indoor accelerated corrosion test spectrum comprises test conditions and test time; the test conditions are matched with the corrosive environment factors; the trial time and the duration are matched.
3. The design method of claim 1, further comprising:
acquiring corrosion environment factors and atmospheric monitoring data corresponding to the application environment;
and processing the atmospheric monitoring data according to the corrosive environment factors to obtain the corrosive environment data.
4. The design method of claim 3, further comprising:
obtaining corrosion data of a material to be tested placed in the application environment and corresponding atmospheric environment data; wherein the atmospheric environmental data comprises a plurality of environmental factors;
and screening the plurality of environmental factors by a preset feature selection method according to the corrosion data and the atmospheric environmental data to determine the corrosion environmental factors.
5. The design method according to claim 4, wherein the determining step of screening the plurality of environmental factors according to the corrosion data and the atmospheric environmental data by a preset feature selection method to determine the corrosion environmental factors specifically comprises:
preprocessing the atmospheric environment data to obtain preprocessed data;
taking the corrosion data as a reference sequence, taking each environmental factor in the preprocessed data as a comparison sequence, and calculating grey correlation degree;
and determining the corrosive environment factors according to the grey correlation degree and preset screening conditions.
6. The design method according to claim 4, wherein the determining step of screening the plurality of environmental factors according to the corrosion data and the atmospheric environmental data by a preset feature selection method to determine the corrosion environmental factors specifically comprises:
preprocessing the atmospheric environment data to obtain preprocessed data;
performing principal component analysis and establishing a logistic regression model according to the corrosion data and the preprocessing data;
obtaining a regression equation comprising a plurality of environmental factors by using an inverse transformation method according to the principal component analysis result and the logistic regression model;
and determining the corrosion environment factors according to the coefficient absolute values of the plurality of environment factors in the regression equation and preset screening conditions.
7. The design method of claim 1, wherein the corrosive environment cumulative spectrum comprises a plurality of corrosion states and durations thereof;
the step of converting the corrosion environment cumulative spectrum into a first corrosion equivalent in a preset standard state specifically includes:
obtaining a first corrosion current density of a material to be tested in a preset standard state;
obtaining a second corrosion current density of the material to be tested in a test state;
determining an environment equivalent conversion coefficient of the material under a test state relative to a preset standard state according to the first corrosion current density and the second corrosion circuit density;
matching each corrosion state with the test state, and determining an environment equivalent conversion coefficient corresponding to each corrosion state;
and counting to obtain a first corrosion equivalent according to the environment equivalent conversion coefficient and the duration of each corrosion state.
8. The design method of claim 1, wherein the indoor accelerated corrosion test spectrum comprises a plurality of test conditions;
the step of converting the indoor accelerated corrosion test spectrum into a second corrosion equivalent in a preset standard state specifically includes:
obtaining a first corrosion current density of a material to be tested in a preset standard state;
obtaining a third corrosion current density of the material to be tested under the test condition;
determining a test equivalent conversion factor of the material under test conditions relative to a preset standard state according to the first corrosion current density and the third corrosion current density;
matching each test condition with the test condition, and determining a test equivalent conversion coefficient corresponding to each test condition;
and counting the second corrosion equivalent according to the test equivalent conversion coefficient.
9. The design method according to claim 1, wherein the total duration of the accelerated corrosion test is determined according to the number of cycles and the single cycle time of the indoor accelerated corrosion test spectrum; adjusting the indoor accelerated corrosion test spectrum and re-determining the cycle number according to the total duration and the corrosion characteristics of the material; the corrosion characteristics are determined from corrosion data of the material to be tested placed in an application environment.
10. The design method of claim 1, wherein the sample mode of the indoor accelerated corrosion test spectrum is selected from one of periodic immersion and circulating salt fog.
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