b'Aerospace | Engineer InnovationSimcenter STAR-CCM+Figure 2: The problematic F-22 Raptor jet with a US$228 millionFigure 3: Corrdesa corrosion analysis engineering workflowcorrosion repair tagIs the simulation science solid?manufacturers were usingairframe. In other aircraft systems? Simulation needs proof. In a strictpolytetrafluoroethylene-filled electrolessThousands more. Finding problematic military design environment, the neednickel (EN-PTFE) on aluminum because itinterfaces, bushings and fasteners for verification and validation is evenmet the requirements for conductivity.among these is a nightmare. Needle, greater. The updated military standardsBut corrosion analysis and US Navymeet haystack. and Corrdesas involvement in the SBAtesting showed EN-PTFE connectors program have opened the door forcorroding cadmium from matedThe answer, according to Alan, is another greater acceptance of corrosionconnectors, and accelerating galvanicSiemens PLM software already being simulation. To add to this, Corrdesascorrosion of aluminum electrical boxes.widely adopted by Navy and Air Force design method was validated againstorganizationsTeamcenter. Teamcenter many existing cases.A perfect fit for Siemens PLM software is end-to-end Product Lifecycle I picked Simcenter STAR-CCM+ becauseManagement (PLM) software, When compared against test data fromof the multiphysics capabilities to modelintegrating information, data, processes accelerated tests for NAVAIR galvaniccorrosion, fluid film, thin film,and people throughout a products life. coupons, the 1D method gave acceptablecondensation, etc. I can quickly andTeamcenter can identify and document predictions for bulk electrolyteaccurately calculate electrolyte thickness,thousands of interfaces and materials. conditions. The 3D CAE approach,choose the correct polarization, materialDesigners and maintainers can also accounting for film thickness and fluiddata and calculate corrosion rateaccess all the electrochemical data, Djinn film, improved prediction for thindistribution, says Alan. By hooking intoand Simcenter STAR-CCM+ within electrolyte films. Both quantitatively anda well-respected, verified and validatedTeamcenter. For Alan, corrosion and qualitatively, good predictions werecode like Simcenter STAR-CCM+ whichSiemens PLM software are a perfect fit. achieved with different test chamberour customers already use and have paid results to validate the approach.for, I can quickly assess the materials,Corrdesas corrosion resistant design choose the best option and minimizephilosophy and Siemens PLM Software But would it work in a real-life scenario?testing. Everyone wins. have offered a blueprint to tackle the On many of the Navys F-18 aircraft,enormous problem of corrosion. nfastener holes corrode heavily. RepairOn average, there are thousands of involves inserting a stainless steelbushings and fasteners just in the bushing or replacing a smaller bushing with a larger one. Galvanic tables point to 15-5 PH/Bare Al coupled fasteners asRealitythe answer. However, corrosion analysisCR mircon/yr CR mircon/yrby Simcenter STAR-CCM+ and Djinn tells0.081998 114.27a different story. Simulation shows that0.065599 91.417not only is Ti6Al4V/anodized Al a better0.049199 68.562combination, but that the best solution is to modify the bushing to reduce0.032799 45.708oxidation.0.016400 22.854TI SS TI SS CorrosionCorrosion0.000000.00000 Rate 50mRecently, a French electrical connectorPrediction Rate Bulk J(mA/m2)manufacturer couldnt meet the contact resistance requirements while using aFigure 4: Test vs.Figure 5: Corrosion rate on uncoated lug/bushing in an F-18 aircraftSimcenter STAR-CCM+ new material (a zinc nickel combination).prediction for NAVAIR To meet the requirements,Galvanic coupons 11'