This paper describes a complete vehicle corrosion simulation and modeling tool called ACES (Accelerated Corrosion Expert Simulator) that has a high degree of correlation to actual accelerated corrosion durability test (ACDT) data. The system imports existing 3-D geometric models of full vehicles. An integrity check is conducted to determine if there are missing or improper entities or properties and a report is issued to the user describing the inconsistencies and remedies for solution.  A Software Wizard guides the user through adding fastener and bonding (welds, rivets, etc.) as well as coating system detail.  Crevices, areas for poultice entrapment and location of drainage problems are identified for use by the corrosion/ coating deterioration algorithms. 
A variety of AI solution methods are used depending on the failure mechanism for corrosion and coating breakdown being analyzed.  A knowledge base assembled from Subject Matter Experts, prior ACDT and laboratory test data, and field observations is used by the algorithms.   The tool includes a robust Knowledge Acquisition Facility that incorporates learning algorithms for semi-automatic updating of the models as new experimental or field data is obtained; as well as an Explanation Facility and Design Review Advisory Facility