Simulation of Corrosion Cracking in Reinforced Concrete Based on Multi-Phase Multi-Species Electrochemical Phase Field Modeling

Non-uniform corrosion cracking in reinforced concrete buildings constitutes a fundamental difficulty resulting in durability failure. This work develops a microscopic-scale multi-species electrochemical phase field model to tackle this issue. The model comprehensively examines the spatiotemporal coupling mechanisms of the full “corrosion-rust swelling-cracking” process by integrating electrochemical reaction kinetics, multi-ion transport processes, and a unified phase field fracture theory. The model uses local corrosion current density as the primary variable to accurately measure the dynamic interactions among electrochemical processes, ion transport, and rust product precipitation. It incorporates phase field method simulations of fracture initiation and propagation in concrete, establishing a bidirectional link between rust swelling stress and crack development. Experimental validation confirms that the model’s predictions about cracking duration, crack shape, and ion concentration distribution align well with empirical data, substantiating the efficacy of local corrosion current density as an indicator of electrochemical reaction rate. Parametric studies were performed to examine the effects of interface transition zone strength, oxygen diffusion coefficient, protective layer thickness, reinforcing bar diameter, and reinforcing bar configuration on cracking patterns. This model’s multi-physics field coupling framework, influenced by dynamic corrosion current density, facilitates cross-field interactions, offering sophisticated theoretical tools and technical support for the quantitative analysis, durability evaluation, and protective design of corrosion-induced cracking in reinforced concrete structures.