Innovative Approaches for Predicting Galvanic Effects of Dissimilar Material Interfaces

Aircraft design is based on mechanical performance, but corrosion (especially galvanic corrosion) is the primary driver for sustainment cost, and initiates mechanical failure in Naval aircraft. Computational corrosion solutions are being developed by the ONR SBA Team. Our Phase 1 and Phase 2 programs successfully demonstrated that GalvanicMaster finite element analysis (FEA) accurately reproduces galvanic corrosion risk, location and relative severity in complex assemblies. Modeling has been validated against sustainment experience, and formal VV&A per MIL-STD-3022 is underway. GalvanicMaster now includes Time Stepping and resistive surface layers, permitting incorporation of paints, anodize, and corrosion products. We have developed a simplified approach usable by designers and non-FEA engineers for quick corrosion analysis and scoping. In Phase 2.5 we will formally validate both the simplified and FEA software, and integrate the simplified system into CAD. We will analyze a range of situations, including OEM and sustainment corrosion issues and experimental setups of SBA team members. We will further develop the data acquisition Best Practices and Data Management System to assemble the database. The FEA and simplified modeling approaches, as well as the underline data, will be available to SBA Team members and the sustainment community.