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Repeated wet–dry cycle exposure to seawater during ballasting processes hastens the surface corrosion rate. Moreover, the larger volumetric changes of corroded ballast tanks generate lower pitting severity. This paper models the pitting severity of corroded ballast tanks of varying roughness and volumes. Seven rectangular finite elements models with Gaussian rough surfaces are examined. The surface roughness modelling is analyzed with correlation among corrosion-statistical parameters at various corroded specimen volume changes. Additionally, the paper elaborates the severity of pitting corrosion characteristics using the pitting factor and the relationship between the maximum and average pit depth. The pitting severity – volumetric changes scenario investigates the model’s stress distribution, showing that the greater change in volume and lower pitting severity tend to have a lower stress distribution, which is randomly concentrated on the larger area. Comparison of the theoretical results with physical test data using 3D laser scans indicates a close match.

Numerical analysis of the correlation between the pitting severity and surface roughness of corroded specimens