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A us tralian Journal of Bas ic and A pplied Sciences , 3(3): 2801-2808, 2009

ISSN 1991-8178
2009, INSInet Publication

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.
Abs tract: The work s tudied the development of s oftware for q uick es timation of the corros ion
properties of aus tempered ductile iron. The already developed and validated model equations done by
us were us ed to develop the algorithm, the flowchart and coding. This was us ed to develop computer
s oftware named OYEA DE CORRO M A NA GER-2007 us ing Vis ua l Bas ic Programming language for
rapid implementation of developed model. The res ults of the developed s oftware were printed out from
computer output s amples interfaces as outputs . Finally , t he OYEA DE CORRO M A NA GER-2007 was
recommended for oil companies , automobile, foundry and manufacturing indus tries , res earch ins titutes
and tertiary ins titutions s uch as univers ities that undertake cours es in materials s ciences / engineering
and indus trial chemis try.
Key words : Development, s oftware, corros ion properties , model and aus tempered ductile cas t iron
INTRODUCTION
Ductile iron is the mos t recent type of cas t iron and, the fas tes t growing ferrous allo y b e c a u s e it can be
p ro d u c e d from a low cos t melting furnace s uch as cupola. The eutectic s tructure cons is ts of the gamma-iro n
a n d g ra p h it e where graphite takes the s hape of s pherical nodules (due to the nodularizing effect of element s
s uch as magnes ium and/ or cerium in the melt) ins te a d of the flakey s hape as in grey cas t iron. Thes e
elemen t s a ffect the graphite in the melt by altering its s urface tens ion and caus ing it to nucleate as s pheroids
(W alton, 1971). There are various types o f ductile iron ranging from ferritic, pearlitic, ferritic-pearlitic,
aus tenitic, bainitic and aus tempered ductile irons (www.ductile.org).
The s erious cons e q u e nces of the corros ion proces s have become a problem of worldwide s ignificance. In
a d d it ion to our everyday encounters with this form of degradation, corros ion caus es plant s hutdowns , wa s t e
of valuable res ourc e s , lo s s or contamination of product, reduction in efficiency, cos tly maintenance, and
expens ive overdes ign; it als o jeopardizes s afety and inhibits technological progres s (Roberge, 2000).
Predictive modeling and s tatis tical proces s control have become integral components of the modern s cience
a n d e n g ineering of complex s ys tems . The mas s ive introduction of computers in the workplaces has als o
dras tically changed the importance of thes e machines in daily operations . Computers play important roles in
data acquis ition in laboratory and field environments , data proces s in g a n d a nalys is , data s earching, and data
pres entation in unders tandable and us eful formats . Computers als o as s is t engineers in tran s fo rmin g data into
us able and relevant information (Roberge, 2000).
A utomobile, foundry and manufacturing indus t rie s w ill find the s oftware very us eful. Res earch ins titutes
and u nivers ities that carry out res earches on corros ion properties of ductile iron are expected to als o utilize
the s oftware.
Aim and Objectives:
The aim of this work is to develop computer s oftware that could be us ed to es tima t e t h e corros ion
properties of aus tempered ductile iron. W hile the s pecific objectives are:
C

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

Corresponding Author: Oyetunji A, Department of M etallurgical and M aterials Engineering, Federal University of
Technology, Akure, Nigeria.
E-mail: akinlabioyetunji @yahoo.com
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MATERIALS AND METHODS
M ethod:
The s oftware was developed through the us e of developed and validated models that es timate (i) corros ion
rate without initial knowledge of affordable weight los s , (ii) corro s io n rate with initial knowledge of affordable
weight los s ; and generate the theoretical data.
Sourced for the available programming languages that can be employed in the s oftware development; s elect
the appropriate one t h a t g iv e s details of the problems and that entails the us e of flowchart, algorithm and
coding.
Tes t run the program and debug for errors ; acquis ition of d a t a for running the program, validation of the
s oftware, and s tate the computer configuration that will be needed for the work.
M aterials:
The materials us ed were cas t aus tempe re d ductile iron and analyzed with chemical compos itions s hown
in Table 1, different media (Tetra oxo-s ulphate (VI) acid (H 2 S O 4 ) and Sodium chloride (NaCl) and
concentrations (0.5M and 2.0M ).
M odel Formulation:
The developed a n d v a lid a t e d models were us ed for the development of the s oftware. This model was in
two forms ; o n e w it h c o rros ion rate us ing weight los s , and the s econd form having corros ion rate without
weight los s .
The model equations us ed were pres ented in equations 1 - 4.
For NaCl
(1)

(2)
For H2 SO4
(3)

(4)
W here y = Corros ion rate in mil per ye a r (mp y ), x1 = Time in days , x2 = Cumulative weight los s in
milligrams (mg), x3 = PH, and x4 = Potential difference in millivolts (mV).
Software Development:
The s oftware named OYEA DE CORROM A NA GER 2007 was finally developed from already deve loped
and validated model as contained in equations 1-4 us ing the Vis ual Ba s ic P ro gramming language (Holzner,
1998, Schneider, 1999 and www.zdu.com) bec a u s e of its flexibility and us ers friendlines s . It involves des ign
of a flowchart and algorithm, creation of interfaces , s etting the controls properties and writing of codes .
The flowchart was developed as s hown in Fig. 1. The alg o rithm and coding were equally developed as
s hown in appendices 1 and 2. The databas e was create d a n d t h e in t e rface that allows for inputting of
parameters s hown in Fig 2 was equally developed for eas y us age.
Validation of the Developed Software:
The developed s oftware was validated us ing the exis ting experimental and s ome other d a t a with
c o n centrations of 0.5M and 2.0M in H2 SO4 and NaCl. This was done through s tatis tical analys is where t h e
us e of both correlation coefficient and s tandard erro r t e s ts were us ed. The res ults of thes e tes ts were s hown
in Tables 2 and 3. T h e s a mp le s o f o utputs printed for 0.5M and 2,0M for H2 SO 4 and NaCl res pectively were
s hown in Figs . 3 4.

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

Fig. 1:

Flowchart for the Developed s oftware tha t es timates the corros ion rate of A us tempered Ductile
Iron.

Computer Configuration:
The developed s o ft w a re ru n s on any of thes e computer s ys tems : Pentium II, III, IV and M with Vis ta of
any of thes e minimum configurations of 10GB Capacity, 64M B RA M and printer.
RES ULTS AND DIS CUS S ION
Results:
The res ult of c h e mic a l a n alys is on aus tempered ductile iron was s hown in Table 1 and validation tes t
res ults w e re s hown in Tables 2 and 3. The flowchart was s hown in Fig. 1. The interface that allows for
input t in g of parameters was s hown in Fig 2 while Figs 3 and 4 s how the s amples of output res ults printed
from developed s oftware. The algorithm and coding were in appendices 1 and 2 res pectively.

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T he 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
Ti
Al
B
Cu
% Contents
0.263
0.0105
0
0.024
0.096
0.017
0.007
0.008
Table 1:

Fig. 2:

Sample of the interface.

Fig. 3:

Output for 0.5M H2 SO4 and NaCl

Discussions:
From the correlation coefficient and s tandard error tes ts res ults tes t s hown in Tables 2 and 3 all the
corros ion ra t e s (with and without weight los s ) for both numerical (data us ing model equations ) and
computerized data (data generated us ing developed s oftware) pos s es s ed high pos itive correlation. This s hows
that the data have excellent reliability (A deroba, 1995 and Okoko, 2000).
The s tandard erro r t e s t re s u lts for both numerical and computerized data in Tables 2 and 3 als o s howed
that there was good agreement between the t w o d a t a . A s n o n e of the s tandard error for any of the data
exceeded 8%, hence they can be neglected (Kus iak and Kuziak, 2002).

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Table 2:

S/N
1
2
3
4
5
S/N
1
2
3
4
5

Correlation Coefficient and Standard Error T ests Results of Corrosion Rate (with W eight loss) for ADI
and NaCl Media.
(a) H2 SO4
Media Concentration (M)
Correlation Coefficient
0.050
0.973
0.100
0.920
0.150
0.850
0..200
0.900
0..300
0.940
(b) NaCl
Media Concentration (M)
Correlation Coefficient
0.050
0.840
0.100
0.900
0.150
0.820
0..200
0.850
0..300
0.870

immersed i n H 2 SO4

Standard Error
3.500
3.850
4.050
3.600
3.500
Standard Error
3.600
3.100
3.900
3.500
3.300

S/N
1
2
3
4
5

Correlation Coefficient and Standard Error T ests Results of Corrosion Rat e (w i t h o u t W eight loss) for ADI immersed in H 2SO 4
and NaCl Media.
(a) H2 SO 4
Media Concentration (M)
Correlation Coefficient
Standard Error
0.050
0.820
4.300
0.100
0.800
4.100
0.150
0.815
4.150
0..200
0.840
3.850
0..300
0.835
3.950
(b) NaCl
Media Concentration (M)
Correlation Coefficient
Standard Error
0.050
0.860
2.300
0.100
0.825
3.600
0.150
0.837
3.500
0..200
0.840
3.420
0..300
0.857
3.310

Fig. 4:

Output for 2.0 M H2 SO 4 and NaCl

Table 3:

S/N
1
2
3
4
5

The s oft w a re w o rked perfectly very well. It worked fas ter than any iteration methods . The numerical and
computerized data (with and without weight los s ) obtained us ing the s oftware for aus tempered d u c t ile irons
immers ed in 0.5M and 2.0M chloride and s ulphate media compared favorably with each other.
Finally, as there was good agreement between the numerical an d c o mp u t e rize d data for all the corros ion
rates (with and withou t weight los s ); the developed s oftware was valid and can be us ed to evaluate corros ion
rates (with and without weight los s ) properties of the aus tempered ductile iron s tudied.
Conclusion:
The objectives o f d e v e lo p ing s oftware that will rapidly es timate the corros ion properties of aus tempered
d u c tile iron were achieved. Hence, this work will provide quick information on the corros ion degradation o f
aus tempered ductile iron materials in corros ive environments .
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Recommedation:
The s oftware was recommended to oil and gas companies , automobile, fo u n d ry and manufacturing
indus tries that us es or will be us ing A DI. Res earch ins titutes and tertiary ins titutions s uch as univers ities that
work on corros ion properties of A DI can s till benefit from t h e u s e of this developed s oftware. Finally, further
works on the development of both models and s oftware that will es timate the corros ion p ro perties of other
types of ductile irons are s till in progres s .
Appendix 1: Algorithm of the Developed Softwate:
C
C
C
C
C
C

Select the material type.


If the material is nodular cas t iron, dis play the interface for corros ion es timation.
Select method.
Input type of nodular cas t iron, medium, concentration, potential difference, pH, weight los s (optional) and
time.
Es timate corros ion rate.
Print corros ion rate.

Appendix 2: Coding of the Developed Software:


Private Sub cmdcheck_Click()
cmdmtltype.Vis ible = 1
cmdcheck.Vis ible = 0
cmdmtl.Vis ible = 0
End Sub
Private Sub cmdmtl_Click()
frmanalys e.Show
End Sub
Private Sub cmdmtltype_Click()
If txtc.Text = "" Or txts i.Text = "" Or txtce.Text = "" Then
M s gBox "Enter the compos ition", vbCritical, "Invalid Entry"
txtc.SetFocus
Els eIf txtc.Text < 0.008 A nd txts i.Text = 0 A nd txtce.Text = 0 Then
lbldis play.Caption = "Commercial Pure Iron"
Els eIf txtc.Text >= 0.008 A nd txtc.Text < 0.25 A nd txts i.Text = 0 A nd txtce.Text = 0 Then
lbldis play.Caption = "Low Carbon Steel"
Els eIf txtc.Text >= 0.25 A nd txtc.Text < 0.6 A nd txts i.Text = 0 A nd txtce.Text = 0 Then
lbldis play.Caption = "M edium Carbon Steel"
Els eIf txtc.Text >= 0.6 A nd txtc.Text < 1.4 A nd txts i.Text = 0 A nd txtce.Text = 0 Then
lbldis play.Caption = "High Carbon Steel"
Els eIf txtc.Text >= 2.14 A nd txtc.Text <= 4.5 A nd txts i.Text = 0 A nd txtce.Text = 0 Then
lbldis play.Caption = "Commercial Cas t Iron"
Els eIf txtc.Text >= 2 A nd txtc.Text <= 4.5 A nd txts i.Text >= 1 A nd txtce.Text = 0 Then
lbldis play.Caption = "Grey Cas t Iron"
Els eIf txtc.Text >= 3 A nd txtc.Text <= 4 A nd txts i.T e xt > = 1.8 A nd txts i.Text <= 2.8 A nd_ txtce.Text >= 0.1
A nd txtce.Text <= 1 Then
lbldis play.Caption = "Nodular Cas t Iron"
cmdmtltype.Vis ible = 0
lbldis play.Vis ible = 1
cmdmtl.Vis ible = 1
cmdcheck.Vis ible = True
End If
End Sub
Private Sub Form_Load()
cmdmtl.Vis ible = Fals e
cmdcheck.Vis ible = Fals e
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End Sub
Private Sub cbomedium_Click()
If cbotype.Text = "" Then
M s gBox "You mus t s elect the type of ductile iron", vbOKOnly + vbCritical, "Retry _Later"
cbotype.Text = ""
End If
End Sub
Private Sub cbotype_click()
If cbotype.Text = "A us tempered Ductile Iron (A DI)" Then
cbomedium.Clear
cbomedium.A ddItem "H2SO4"
cbomedium.A ddItem "NaCl"
Els e
cbomedium.Clear
M s gBox "This feature is not incorporated", vbOKOnly + vbCritical, "Retry Later"
End If
End Sub
Private Sub cmdes timate_Click()
Dim x1, x2, x3, x4 A s Double
x1 = Val(txttime.Text)
x2 = Val(txtwtlos s .Text)
x3 = Val(txtph.Text)
x4 = Val(txtpd.Text) / 1000
If Optchoos e(0) = True Then
If cbomedium.Text = "" Or cboconc.Text = "" Then
M s gBox "You mus t s e le c t t h e me d iu m a n d concentration", vbOKOnly + vbCritical, _"Retry Later"
Els eIf cbomedium.Text = "NaCl" A nd cboconc.Text = "0.5" Then
txtcorrate.Text = Format((-0.00457 + 0.000054 * x1 - 0.000308 * x3 - 0.014271 * x4),
_"####0.000000")
Els eIf cbomedium.Text = "NaCl" A nd cboconc.Text = "2.0" Then
txtcorrate.Text = Format((0.030019 - 0.000336 * x1 - 0.003922 * x3 - 0.013176 * x4),_
"####0.000000")
Els eIf cbomedium.Text = "H2SO4" A nd cboconc.Text = "0.5" Then
txtcorrate.Text = Format((0.000514 - 0.00006 * x1 + 0.000899 * x3 + 0.001937 * x4),_
"####0.000000")
Els eIf cbomedium.Text = "H2SO4" A nd cboconc.Text = "2.0" Then
txtcorrate.Text = Format((0.080974 - 0.002322 * x1 - 0.029211 * x3 + 0.06809 * x4),_
"####0.000000")
End If
Els e
If cbomedium.Text = "" Or cboconc.Text = "" Then
M s gBox "You mus t s elect the medium and concentrat io n " , v b O K O n ly + v b Critical,_ "Retry Later"
Els eIf cbomedium.Text = "NaCl" A nd cboconc.Text = "0.5" Then
t xt c o rrate.Text = Format((-0.005912 - 0.000053 * x1 + 0.092046 * x2 + 0.000316 * x3 -_ 0.009425
* x4), "####0.000000")
Els eIf cbomedium.Text = "NaCl" A nd cboconc.Text = "2.0" Then
txtcorrate.Text = Format((-2.511663 - 0.00003 * x1 + 134.608761 * x2 - 0.004062 * x3_ - 0.01096
* x4), "####0.000000")
Els eIf cbomedium.Text = "H2SO4" A nd cboconc.Text = "0.5" Then
txtcorrate.Text = Format((-0.001366 - 0.000051 * x1 - 0.433192 * x2 + 0.001395 * x3 - _ 0.001064
* x4), "####0.000000")
Els eIf cbomedium.Text = "H2SO4" A nd cboconc.Text = "2.0" Then
txtcorrate.Text = F o rma t ((-0.013395 + 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 = ""
txtwtlos s .Text = ""
txtph.Text = ""
txtpd.Text = ""
txtcorrate.Text = ""
cboconc.A ddItem "0.5"
cboconc.A ddItem "2.0"
cbomedium.A ddItem "NaCl"
cbomedium.A ddItem "H2SO4"
End Sub
Private Sub Form_Load()
M e.Left = (Screen.W idth - M e.W idth) / 2
cbomedium.Clear
txttime.Text = ""
txtwtlos s .Text = ""
txtph.Text = ""
txtpd.Text = ""
txtcorrate.Text = ""
txtwtlos s .Vis ible = Fals e
Label3.Vis ible = Fals e
cbomedium.A ddItem "NaCl"
cbomedium.A ddItem "H2SO4"
End Sub
Private Sub Optchoos e_Click(Index A s Integer)
Dim p A s Integer
p = Optchoos e(Index).Index
If p = 0 Then
txtwtlos s .Vis ible = Fals e
Label3.Vis ible = Fals e
Els e
txtwtlos s .Vis ible = True
Label3.Vis ible = True
End If
End Sub
REFERENCES
A deroba, A .A ., 1995. Tools of Engineering M anagement (Engineering Project M anagement. Vo l 1. Bes ade
Nig. Ltd: Ondo Nigeria, pp: 20.
Holzner, S., 1998. Vis ual Bas ic 6 Black Book, The Coriolis Group., pp: 3-20.
K us iak, J. and R. Kuziak, 2002. M odelling of micros tructure and mechanical properties of s t e e l u s in g t h e
artificial neural network. Journal of M aterials Proces s ing Technology. 127(1): 115-121.
Okoko, E., 2000. Quantitative Techniques in U rb a n a n a lys is . Kras t Books Limited: Ibadan Nigeria,
pp: 17-185.
Roberge, P.R., 2000. Handbook of Corros ion Engineering, M cGraw-Hill, USA .
Schneider, D.I., 1999. Compu t e r Programming Concepts and Vis ual Bas ic, Pears on Cus tom Publis hing.
W alton, C.F., 1971. Gra y a n d D u c t ile Iron Cas tings Handbook; including data on Gray, Ductile, W hite
and High A lloy Irons , Gray and Ductile Iron Founders Society Inc., pp: 52-53, 99, and 313-314.
www.ductile.org, Ductile Iro n D a t a; RIO Tinto Iron and Titanium Inc (1990), Canada, s ection 2., pp5-7.
www.zdu.com, ZDU Student M anual, 1998. Java Programming: Part 1.

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