development of software for estimation of the corrosion

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Au st ralian Journal o f Basic and Ap plied Sciences , 3(3): 2801-2808, 2009

ISSN 1991-8178

© 2009, INSInet Publication

Corresponding Author: Oyetunji A, Department of M etallurgical and Materials Engineering, Federal University of

Technology, Akure, Nigeria.E-mail: akinlabioyetunji @yahoo.com

2801

Development of Software for Estimation of the Corrosion

Properties of Austempered Ductile Iron

Oyetunji A and Adebisi J.A.

Department of Metallurgical and Materials Engineering,

Federal University of Technology, Akure, Nigeria.

Abstract: The work studied the development o f software for q uick estimation of the corrosion

prope rties of austempered du ct ile iron. The already deve loped and v alidated model equ at ions do ne by

us were used to develop the algorithm, the flowchart and coding. This was used to develop computer

software named OYEADE CORRO MANAGER-2007 using Visual Basic Programming language for

rapid implementation of dev eloped model. The results of the developed s oftware were p rinted out from

compute r outpu t samples’ interfaces as o utp uts . Finally , t he OYEADE CORRO MA NAGER-2007 was

recommended for oil companies, automobile, foundry and manufacturing industries, research institutesand tertiary institutions such as universities that undertake courses in materials sciences/ engineering

and industrial chemistry.

Key words: Development, software, corros ion properties, model and aust empered du ctile cas t iron

INTRODUCTION

Ductile iron is the most recent type of cast iron and, the fastest growing ferrous allo y b ec au s e it can be

p ro d u c ed from a low cost melting furnace such as cupo la. The eutect ic structure cons ist s of the gamma- ir o n

a n d g ra p h it e where graphite takes the sha pe of spherical nodu les (due to the nod ularizing effect of element s

su ch as magnesium and/ or cerium in the melt) ins te ad of the flakey shape as in grey cast iron. These

elemen t s a ffect the graphite in the melt by altering its surface tension and cau sing it to nucleate as spheroids

(Walton, 1971). There are v arious typ es o f duct ile iron ranging from ferritic, pearlitic, ferritic-pearlitic,austenitic, bainitic and austempered ductile irons (www.ductile.org).

The s erious cons eq u e nces of the corrosion process have beco me a problem of worldwide s ignificance. In

ad d ition to our everyday encounters with this form of degradation, corrosion causes plant s hutdowns, was te

of valuable resource s , lo s s or cont amination of product, reduction in efficiency, cost ly maintenan ce, and

expensive overdesign; it also jeopardizes safety and inhibits technological progress (Roberge, 2000).

Predictive modeling and sta tistical proces s control hav e become integral components of the modern science

a n d e n g ineering of complex sy stems. The mass ive introduction of computers in the workplaces has also

drastically changed the importance of these machines in daily operations. Computers play important roles in

data acquisition in laboratory and field environments, data proces sin g an d a nalysis, data searching, and data

pre senta tion in un de rstandab le and us eful formats . Co mput ers also as s ist engineers in tran s fo rmin g da ta into

usable and relevant information (Roberge, 2000).

Aut omobile, foundry and manufacturing indust rie s wil l find the s oftware very useful. Research inst itutes

and u niversities that carry ou t researches on co rrosion p roperties of ductile iron are expected to also utilizethe software.

Aim and Object ives:

The aim of this work is to develop computer software that could be used to estimate the corrosion

pro pe rties of austempered du ct ile iron. W hile the specific ob ject ives are:

Develop flowchart an d a lg o rithms from already developed models; and (ii) validation of the develop

software.



Aust. J. Basic & Appl. Sci., 3(3): 2801-2808, 2009

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MATERIALS AND METHODS

Method:

The s oftware was developed through the us e of developed and validated models th at es timate (i) corrosion

rate without initial knowledge of affordable weight los s, (ii) corro s io n rate with initial knowledge of affordableweight loss; and generate the theoretical data.

Sourced for the available programming languag es that can be employed in the s oftware development; select

the appropriate one t h at g iv es details of the problems and th at entails the us e of flowchart, algorithm and

coding.

Test run the program and debug for errors; acquisition of data for running the program, validation of the

so ftware, and s tate th e computer configuration th at will be needed for the work.

Materia ls:

The materials used were cast austempered ductile iron and analyzed with chemical compositions shown

2 4in Table 1, different media (Tetra –oxo-sulphate (VI) acid (H SO ) and Sodium chloride (NaCl) and

concent rations (0.5M and 2.0M).

Mode l Fo rmula tion:The developed a n d v alid at ed models were used for the development of the software. This model was in

two forms; o n e wit h co rros ion rate using weight loss, and the second form having corrosion rate withou t

weight loss.

The model equations used were presented in equations 1 - 4.

For NaCl

(1)

(2)

2 4For H SO

(3)

(4)

1 2W here y = Corrosion rate in mil per ye ar (mp y ), x = Time in days , x = Cumulative weight loss in

3 H 4milligrams (mg), x = P , and x = Poten tial difference in millivolts (mV).

Softw are Deve lo pm ent:

The software named OYEADE CORROMANAGER 2007 was finally developed from already developed

and v alidated model as cont ained in equ ations 1-4 using th e Visual Ba s ic Pr o gramming languag e (Holzner,1998, Schne ider, 1999 and www.zdu.co m) bec a u s e of its flexibility and us ers friend lines s. It involves d es ign

of a flowchart and algorithm, creation of interfaces, setting the controls’ properties and writing of codes.

The flowchart was dev eloped as sho wn in Fig. 1. The alg o rithm and coding were equally dev eloped as

shown in appendices 1 and 2. The database was created and the interface that allows for inputting of

pa rameters sho wn in Fig 2 was equally deve loped for eas y us age.

Valida tion of the Developed Software:

The dev eloped software was validated u sing the existing experimental and s ome other d at a with

2 4co n centrations of 0.5M and 2.0M in H SO and NaCl. This was done through statistical analysis where th e

us e of both correlation coefficient and standard erro r t es ts were used . The results of thes e tests were shown

2 4in Tables 2 and 3. Th e s amp les o f o utputs printed for 0.5M and 2,0M for H SO and NaCl respectively were

shown in Figs. 3 – 4.




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Fig. 1: Flowchart for the Developed software tha t estimates the corrosion rate of Aus tempered Ductile

Iron.

Computer Configuration:

The developed s o ft wa re ru n s on any of these computer sys tems: Pentium II, III, IV and M with Vista of

any of these minimum configurations of 10GB Capacity, 64MB RAM and printer.

RESULTS AND DISCUSS ION

Result s:

The result of chemical analysis on austempered ductile iron was shown in Table 1 and validation test

results were shown in Tables 2 and 3. The flowchart was shown in Fig. 1. The interface that allows for

inputting of parameters was shown in Fig 2 while Figs 3 and 4 show the samples of output results printed

from developed software. The algorithm and coding were in appendices 1 and 2 respectively.




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Table 1: The chemical composition of austempered ductile iron

Chemical Analysis, percent (%)

Elements --------- -------- --------- -------- ------------------------------------------------------------------------------------------ --------- --------- -----

Fe C Si Mn P S Cr Mo Ni

% Contents 92 2.97 2.5 0.8 0.156 0.083 0.486 0.216 0.106

Elements Cd Nb Pb Sn T i Al B Cu% Contents 0.263 0.0105 0 0.024 0.096 0.017 0.007 0.008

Fig. 2: Sample of the interface.

2 4Fig. 3: Output for 0.5M H SO and NaCl

Discussions:

From the correlation coefficient and standard error tests results test shown in Tables 2 and 3 all the

corrosion ra t e s (with and withou t weight loss ) for both numerical (data using model equations) and

computerized data (data generated using developed software) possessed high positive correlation. This shows

that the data have excellent reliability (Aderoba, 1995 and Okoko, 2000).

The stand ard error t e s t re s u lts for both numerical and computerized data in Tables 2 and 3 also s howed

that there was good agreement between the tw o d at a. A s n o n e of the standard error for any of the data

exceeded 8%, hence they can be neglected (Kusiak and Kuziak, 2002).




2805

2 4Table 2: Correlation Coefficient and Standard Error Tests Results of Corrosion Rate (with Weight loss) for ADI immersed i n H SO

and NaCl Media.

2 4 (a) H SO

S/N Media Concentration (M) Correlation Coefficient Standard Error

1 0.050 0.973 3.500

2 0.100 0.920 3.850

3 0.150 0.850 4.050

4 0..200 0.900 3.600

5 0..300 0.940 3.500

(b) NaCl


1 0.050 0.840 3.600

2 0.100 0.900 3.100

3 0.150 0.820 3.900

4 0..200 0.850 3.500

5 0..300 0.870 3.300

2 4Table 3: Correlation Coefficient and Standard Error Tests Results of Corrosion Rat e (w i th o u t W eight loss) for ADI immersed in H SO

and NaCl Media.

2 4 (a) H SO


1 0.050 0.820 4.300

2 0.100 0.800 4.100

3 0.150 0.815 4.150

4 0..200 0.840 3.850

5 0..300 0.835 3.950

(b) NaCl


1 0.050 0.860 2.300

2 0.100 0.825 3.600

3 0.150 0.837 3.500

4 0..200 0.840 3.420

5 0..300 0.857 3.310

2 4Fig. 4: Output for 2.0 M H SO and NaCl

The s oft wa re wo rked perfectly very well. It worked faster than any iteration methods . The numerical and

computerized data (with and without weight loss ) obtained using the software for aus tempered d u c t ile irons

immersed in 0.5M and 2.0M chloride and sulphate media compared favorably with each other.

Finally, as there was goo d agreement between the numerical an d co mp u t er ize d data for all the corrosion

rates (with and without weight loss); the developed software was valid and can be used to evaluate corrosion

rates (with an d without weight loss ) properties of the aus tempered d uctile iron stu died.

Conclusion:

The objectives o f d ev e lo p ing s oftware that will rapidly estimate the corrosion properties of austempered

d u c tile iron were achieved. Hence, this work will provide qu ick information on th e corrosion degradat ion o f

austempered ductile iron materials in corrosive environments.




2806

Recommed at io n:

The so ftware was recommended to oil and gas companies, automobile, fo u n d ry and manufacturing

industries that uses or will be using ADI. Research institutes and tertiary institutions such as universities that

work on corrosion properties of ADI can s till benefit from t h e u s e of this developed software. Finally, further

works o n the d evelopment of both models and s oftware that will estimate the corrosion p ro perties o f other types of ductile irons are still in progres s.

Appe ndix 1: Alg orithm of the Dev elop ed Softw ate :

Select the material type.

If the material is nodular cast iron, display the interface for corrosion estimation.

Select method.

Input type of nodular cast iron, medium, concentration, potential difference, pH, weight loss (optional) and

time.

Estimate corrosion rate.

Print corrosion rate.

Appe ndix 2: Cod ing of the Deve lo ped Softw are:

Private Su b cmdcheck_Click()

cmdmtltype.Vis ible = 1

cmdcheck.Vis ible = 0

cmdmtl.Visible = 0

End Sub

Private Sub cmdmtl_Click()

frmanalyse.Show

End Sub

Private Sub cmdmtltype_ Click()

If txtc.Text = "" Or txtsi.Text = "" Or txtce.Text = "" Then

Ms gBox "Enter the compos ition" , vbCritical, "Invalid Entry" txtc.SetFocus

ElseIf txtc.Text < 0.008 And txtsi.Text = 0 And txtce.Text = 0 Then

lbldisp lay.Caption = "Commercial Pure Iron"

ElseIf txtc.Text >= 0.008 And txtc.Text < 0.25 And txtsi.Text = 0 And txtce.Text = 0 Then

lbldisp lay.Caption = "Low Carbon Steel"


lbldisp lay.Caption = "M edium Carbon Steel"


lbldisp lay.Caption = "High Carbon Steel"

ElseIf txtc.Text >= 2.14 And txtc.Text <= 4.5 And txtsi.Text = 0 And txtce.Text = 0 Then

lbldisp lay.Caption = "Commercial Cast Iron"

ElseIf txtc.Text >= 2 And txtc.Text <= 4.5 And txtsi.Text >= 1 And txtce.Text = 0 Then

lbldisp lay.Caption = "Grey Cast Iron"ElseIf txtc.Text >= 3 And txtc.Text <= 4 And txtsi.Text >= 1.8 And txtsi.Text <= 2.8 And_ txtce.Text >= 0.1

And txtce.Text <= 1 Then

lbldisp lay.Caption = "Nod ular Cast Iron"

cmdmtltype.Vis ible = 0

lbldisp lay.Vis ible = 1

cmdmtl.Visible = 1

cmdcheck.Vis ible = True

End If

End Sub

Private Sub Form_Load()

cmdmtl.Visible = False

cmdcheck.Visible = False




2807

End Sub

Private Sub cbomedium_Click()

If cbotype.Text = " " T hen

Ms gBox "You must se lect the type of duct ile iron" , vbOKOnly + vbCritical, "Retry _Later" cbotyp e.Text = ""

End If

End Sub

Private Sub cbotype_click()

If cbotype.Text = "Austempered Ductile Iron (ADI)" Then

cbomedium.Clear

cbomedium.Add Item "H2SO4"

cbomedium.Add Item "NaCl"

Else

cbomedium.Clear

Ms gBox "Th is feature is not incorporated" , vbOKOnly + vbCritical, "Retry Later"

End If

End Sub

Private Su b cmdest imate_ Click()

Dim x1, x2, x3, x4 As Double

x1 = Val(txttime.Text)

x2 = Val(txtwtloss .Text)

x3 = Val(txtph.Text)

x4 = Val(txtpd.Text) / 1000

If Optchoos e(0) = True Then

If cbomedium.Text = "" Or cboconc.Text = "" Then

Ms gBox "You must s ele ct th e med iu m an d concentration", vbOKOnly + vbCritical, _"Retry Later"

Else If cbomedium.Text = "NaCl" An d cbocon c.Text = "0.5" Then

txtcorrate .Text = Format((-0.00457 + 0. 000054 * x1 - 0.000308 * x3 - 0.014271 * x4),

_" ## ## 0.000000") Else If cbomedium.Text = "NaCl" An d cbocon c.Text = "2.0" Then

txtcorrate .Text = Format((0.030019 - 0.000336 * x1 - 0.003922 * x3 - 0. 013176 * x4),_

"####0.000000")

Else If cbomedium.Text = "H2SO4" An d cbocon c.Text = "0.5" Then

txtcorrate .Text = Format((0.000 514 - 0. 00006 * x1 + 0.000899 * x3 + 0.001937 * x4),_

"####0.000000")


txtcorrate.Text = Format((0.080974 - 0.002322 * x1 - 0.029211 * x3 + 0.06809 * x4) ,_

"####0.000000")

End If

Else

If cbomedium.Text = "" Or cboconc.Text = "" Then

Ms gBox "You must select the medium and concentratio n " , v b OKO n ly + v b Critical,_ "Retry Later" Else If cbomedium.Text = "NaCl" An d cbocon c.Text = "0.5" Then

t xt co rrate.Text = Format((-0.005912 - 0.000053 * x1 + 0.092046 * x2 + 0.000316 * x3 -_ 0.00942 5

* x4), "####0.000000")

Else If cbomedium.Text = "NaCl" An d cbocon c.Text = "2.0" Then

txtcorrate .Text = Format((-2.511663 - 0.00003 * x1 + 134.608761 * x2 - 0.004062 * x3_ - 0.01096

* x4), "####0.000000")


txtcorrate .Text = Format((-0.001366 - 0.000051 * x1 - 0.433192 * x2 + 0.001395 * x3 - _ 0. 001064

* x4), "####0.000000")


txtcorrate .Text = Fo rma t (( -0 .0 13395 + 0.000734 * x1 + 2.780626 * x2 - 0.009884 * x3 _+ 0.022314

* x4), "####0.000000")

End If




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End If

End Sub

Private Sub Command3_Click()

cbomedium.Clear cboconc.Clear

txttime.Text = ""

txtwtloss.Text = ""

txtph .Text = ""

txtpd .Text = ""

txtcorrate.Text = ""

cbocon c.AddItem "0.5"

cbocon c.AddItem "2.0"



End Sub

Private Sub Form_Load()

Me.Left = (Screen.Width - Me.W idth) / 2

cbomedium.Clear

txttime.Text = ""

txtwtloss.Text = ""

txtph .Text = ""

txtpd .Text = ""

txtcorrate.Text = ""

txtwtloss.Visible = False

Label3.Visible = False



End Sub

Private Sub Optchoose_Click(Index As Integer)

Dim p As Integer

p = Opt choo se(Index).IndexIf p = 0 Then

txtwtloss.Visible = False

Label3.Visible = False

Else

txtwtloss.Visible = True

Label3.Visible = True

End If

End Sub

REFERENCES

Ad eroba, A.A ., 1995. Tools of Enginee ring Manag ement (Enginee ring Project Man agement . Vo l 1. Besade

Nig. Ltd: Ond o Nigeria, pp : 20.Holzner, S., 1998. Visual Basic 6 Black Book, The Coriolis Group., pp: 3-20.

Kus iak, J. and R. Kuziak, 2002. Mod elling of micros tructure and mechanical properties of st e el u s in g t h e

artificial neu ral network. Journa l of Materials Proces sing Technology. 127(1): 115-121.

Okoko, E., 2000. Quantitative Techniques in U rb a n a n a lys is. Krast Books Limited: Ibadan Nigeria,

pp : 17-185.

Roberge, P.R., 2000. Hand boo k of Corrosion Engineering, McGraw-Hill, USA.

Schne ider, D.I., 1999. Compu t e r Programming Concept s an d Visu al Bas ic, Pearson Cus tom Publishing.

Wa lton, C.F., 1971. Gray an d Du c t ile Iron Castings Handbook; including data on Gray, Ductile, White

and High Alloy Irons, Gray and Ductile Iron Founders’ Society Inc., pp: 52-53, 99, and 313-314.

www.duc tile.org, Ductile Iro n Da t a; RIO Tinto Iron and Titanium Inc (1990), Canad a, section 2., pp5-7.

www.zdu.com, ZDU Student Manua l, 1998. Java Prog ramming: Part 1.

development of software for estimation of the corrosion

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