International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

This study investigates the electrochemical performance of Sacrificial Anode Cathodic Protection (SACP) systems for offshore steel structures using Finite Element Analysis (FEA). Two structural substrates, S235JR carbon steel and S550QL high-strength steel, were modelled in a 3 wt.% NaCl electrolyte. A comparative analysis was performed between two sacrificial anode materials: a conventional Al- 5Mg alloy and a quaternary Al-6Zn-0.2In-1Mg-0.03Ti alloy. The simulations evaluate the influence of anode placement errors by comparing an ideal symmetric distribution (90°) with a clustered configuration (10°). The results show that geometric clustering significantly alters the potential distribution along the structure. For S235JR steel, the clustered configuration produces localized underprotection with potentials reaching −0.78 V (vs. Ag/AgCl). In contrast, for S550QL steel, the same configuration results in localized over-polarization (≈ −0.96 V), thereby increasing the risk of hydrogen-induced stress cracking (HISC). The study demonstrates that improper anode placement may compromise cathodic protection efficiency even when high-performance anode alloys are used. These findings highlight the importance of accurate anode distribution and support the use of numerical simulations in digital twin approaches for offshore corrosion management.

In the chemical industry, heat exchangers play a critical role in maintaining process efficiency. However, these systems are prone to frequent failures, often necessitating extensive maintenance or repairs, which in turn adversely affect the overall economic performance of industrial operations. The chemical industry commonly operates in highly corrosive environments, making corrosion the predominant failure mechanism for heat exchangers. Key factors contributing to corrosion-related failures include defects in fabrication and welding, suboptimal material selection, improper water flow or chemistry management, and the presence of corrosive species in water. This study investigates the corrosion behaviour of heat exchangers under various corrosive conditions, utilizing COMSOL Multiphysics for simulation and analysis.

In the present work, the corrosion of Zn-Ni coated steel in the presence of acetic acid was studied. Corrosion tests were carried out in salt spray and the corrosion rate was determined by the weight loss method. The results showed that the Zn-Ni layer acted as sacrificial coatings on steel, the acetic acid, even if it is a weak acid. Also, in this paper, a simulation was carried out regarding the corrosion protection of steel attacked by acetic acid using a sacrificial anode (Zn alloy). The results obtained from the simulation agree with the experimental ones.