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8/10/2019 Development of Software for Estimation of the Corrosion
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.
8/10/2019 Development of Software for Estimation of the Corrosion
Aust. J. Basic & Appl. Sci., 3(3): 2801-2808, 2009
2802
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.
8/10/2019 Development of Software for Estimation of the Corrosion
Aust. J. Basic & Appl. Sci., 3(3): 2801-2808, 2009
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"
ElseIf txtc.Text >= 0.25 And txtc.Text < 0.6 And txtsi.Text = 0 And txtce.Text = 0 Then
lbldisp lay.Caption = "M edium Carbon Steel"
ElseIf txtc.Text >= 0.6 And txtc.Text < 1.4 And txtsi.Text = 0 And txtce.Text = 0 Then
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
8/10/2019 Development of Software for Estimation of the Corrosion
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