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Corrosion Testing
Corrosion damage is the gradual deterioration of materials, typically metals, due to adverse reactions with the environment, such as exposure to moisture, oxygen, acids and other chemicals.
The consequences of corrosion are extensive, impacting industries by causing structural failures, safety hazards, reduced strength and durability, loss of functionality, and increased maintenance expenses. Detecting the early signs of corrosion is crucial to either repair the damage or replace the affected components promptly.
Corrosion testing helps to analyse the material’s resistance to corrosion or identify any weakness and vulnerabilities. We test a variety of metals, including duplex and austenitic stainless steels and wrought nickel-rich chromium-bearing alloys. Our metallurgical team offers several different corrosion testing methods, including:
- Intergranular Corrosion Testing (IGC)
- Pitting Corrosion Testing
- Corrosion Rate Testing
Our Corrosion Testing Methods
Intergranular Corrosion (IGC)
Intergranular corrosion testing is a method used to evaluate the susceptibility of metallic materials, particularly alloys, to corrosion along grain boundaries. This type of corrosion is known as intergranular corrosion (IGC), and it can significantly impact the mechanical integrity and performance of the material.
Intergranular corrosion occurs in between crystals or grains. If the material become susceptible to corrosion damage, then this can create weaknesses within the material resulting in cracks and deformation. This type of corrosion is often associated with certain alloy compositions, heat treatments, and exposure conditions. Intergranular corrosion is a common concern in stainless steels, aluminium alloys, and other corrosion-resistant alloys.
Intergranular corrosion testing is particularly relevant in industries such as aerospace, petrochemical, and nuclear, where the integrity of materials is vital for safety and reliability. By assessing and mitigating the susceptibility to intergranular corrosion, engineers and materials scientists can make informed decisions to ensure the long-term performance of metallic components.
We work to the following standards:
- Huey Test ASTM A262 – Practice E. is performed to assess attack in austenitic stainless steels.
- ASTM G28 – detects the susceptibility to Intergranular Corrosion in Wrought, Nickel-Rich, Chromium-Bearing Alloys.
Pitting Corrosion Testing
Pitting corrosion testing is a method used to assess the susceptibility of metals to a specific form of localised corrosion known as pitting corrosion.
Pitting corrosion is characterised by the initiation of small, localised pits or craters that form on the material’s surface, which can lead to rapid and deep penetration of the material if left untreated. This type of corrosion can be concerning as it can cause structural damage even when the overall corrosion rate is low.
Pitting corrosion testing provides valuable insights into a material’s susceptibility to pitting corrosion, allowing you to make informed decisions about material selection, design considerations, and corrosion prevention. The goal of pitting corrosion testing is to ensure the long-term reliability and safety of components and structures in corrosive environments.
- Susceptibility & Pitting corrosion is often tested by ASTM G48, Method A (ferric chloride testing). This method looks at Pitting Resistance of Stainless Steels and Related Alloys. A probe of the area with a needle is then carried out to show any hidden pitting.
- A923 Method C, is a Test for detecting the presence of detrimental intermetallic structures in Duplex Stainless Steels.
Rate Corrosion Testing
Corrosion rate testing is used to examine the rate at which corrosion occurs on a material exposed to a corrosive environment.
The corrosion rate is an important parameter for assessing the durability and performance of materials in various applications, especially those exposed to aggressive environments. The testing provides valuable data that helps to anticipate failures, analyse the potential service life of materials, and make informed decisions about corrosion prevention and control measures.
Corrosion rate testing is a valuable test method for industries such as transportation, infrastructure, energy, and manufacturing, where materials are exposed to challenging environmental conditions. The data obtained from corrosion rate testing contributes to the development of corrosion-resistant materials and the implementation of effective corrosion control measures.
Want to know more about our corrosion testing services?
Get in touch today! Get in touch today! Get in touch today!Do you have a question about corrosion testing?
How is corrosion damage detected?
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Corrosion damage can be detected through a variety of testing methods, such as visual inspection, non-destructive testing, and laboratory analysis of samples.
Destructive testing methods can be used to identify corrosion by examining the surface of the material for signs of rust or pitting. Additionally, the material can be cut open to inspect the extent of corrosion within.
To better understand the extent of corrosion damage, it is essential to determine the type of corrosion present. Some common types of corrosion include intergranular corrosion, pitting corrosion, and crevice corrosion. Each type of corrosion can be identified using specific detection methods.
By using the appropriate detection and prevention methods, the negative effects of corrosion can be minimised, and the lifespan of materials can be extended.
What are some early signs of corrosion damage?
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Some early signs of corrosion include discoloration, pitting, roughness, and flaking of the surface. You may also notice a powdery residue or rust-coloured stains on the affected area. It’s important to address these signs promptly to prevent further damage.
These early signs of corrosion damage can include:
- Discoloration or staining on metal surfaces
- Flaking or peeling of paint or coatings
- Formation of rust or white powdery substances on metal
- Pitting or small holes on metal surfaces
- Soft spots or weak areas on metal structures
- Cracks or splits in metal
- Loose or missing fasteners or connections
- Changes in the shape or structure of metal
- Leaks or drips from metal pipes or tanks
- Unusual noises or vibrations from metal equipment
How does corrosion damage affect different metals?
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Different materials are affected by corrosion damage in different ways.
- Rust and discolouration are common forms of corrosion in metals, which occurs when iron or steel reacts with oxygen and moisture in the air.
- Corrosion can weaken the structural integrity of lead-based objects, making them more prone to failure.
- Nickel metals can also experience corrosion damage, causing them to deteriorate over time and resulting in a loss of strength and durability.
- Aluminium and copper metals can also experience corrosion, but they develop a layer on their surface that can slow down the corrosion process.
Are there any metals that are more resistant to corrosion?
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Some metals are well known for their corrosion-resistant properties, such as stainless steel, aluminium, and cupronickel alloys.
Stainless steel contains elements of chromium which helps it to form a naturally occurring, thin oxide layer across the surface of the metal to aid against corrosion damage. This protective coating makes it an extremely useful material for manufacturing a wide range of products and is used across many industries including nuclear and energy, marine and maritime, transportation, and much more.
Aluminium also forms an oxide layer when it encounters oxygen. While aluminium is naturally resistant to corrosion, it can still be affected by certain chemicals or conditions, so it is important to choose the right type of aluminium depending on its intended environment and take appropriate precautions to maintain its integrity.
Cupronickels are known for their excellent corrosion resistance. Some of its other properties and characteristics are good ductility, excellent thermal conductivity, and high electrical conductivity. It is commonly used in marine applications due to its resistance to seawater corrosion and in electrical components due to its conductivity.
Brass is an alloy of copper and zinc, and its corrosion resistance depends on the amount of zinc present. Higher zinc content can improve its resistance to certain types of corrosion.
Bronze is another copper alloy that can be resistant to corrosion, particularly in marine environments. Its resistance comes from the formation of a protective patina on its surface.
Copper itself is known for its excellent electrical conductivity, but it can also be corrosion-resistant in certain applications. Like bronze, copper can develop a patina that helps protect it from further oxidation.
Each of these metals has unique properties that make them suitable for different applications where corrosion resistance is important.
What industries are most affected by corrosion damage?
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Whilst every industry can be affected by corrosion damage, there are certain industries that can experience corrosion more often than others.
- Transportation, Automotive and Aerospace; corrosion can be caused by weather conditions such as heavy rains and increasing flooding risks. This can affect vehicles, trains and train tracks, road traffic systems and safety signs.
- Automotive and Aerospace; corrosion can occur on key components such as jet engines, gearboxes, braking systems which can affect the safety and quality of essential components.
- Marine and Maritime; corrosion is extremely likely due to constant exposure of salt water and harsh environments. Ships, oil rigs and offshore energy systems can all be affected by corrosion.
- Construction; corrosion can affect the durability, safety and structural integrity of bridges, buildings, and other types of infrastructure.
- Energy, Oil and Utilities; corrosion can cause damage to integral pipelines for gas, water and oil supplies which can have an adverse effect on the environment and economy.
- Manufacturing; corrosion of key components and parts, can lead to machine breakdowns or failure of crucial production lines, resulting in significant downtime of equipment and reduced productivity.
It is essential for industries to take a proactive approach to corrosion prevention and mitigation to minimize the risks and costs associated with this pervasive problem.
Is it possible to prevent corrosion damage?
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Choosing the right materials for manufacturing components and products, such a corrosion-resistant alloys and metals, is the first step towards preventing corrosion damage. Factors such as the materials’ exposure to its intended environment, temperature, humidity, and any harsh chemicals or conditions are some key considerations when choosing appropriate materials.
Once the right material has been chosen, protective barriers or coatings on the material should be considered to aid in the prevention of corrosion damage. Coatings such as powders or paints, plating, anodising, and galvanising are all useful methods to give additional protection to a finished product.
Product aftercare is crucial; proper maintenance, such as regular inspection and cleaning of products and components can help detect early signs of corrosion or damage. If the environmental conditions can be controlled (maintaining humidity, temperature, and ventilation levels) they can support the prevention of corrosion damage.
It is important to note that corrosion is not always preventable, but identifying early signs of damage and taking necessary measures means that it can be managed effectively and reduces the likelihood of failure.
What are the economic impacts of corrosion damage?
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The economic impacts of corrosion damage include lost productivity, increased maintenance costs, and reduced lifespan of a product or component.
In addition to the economic impacts, corrosion damage can also have far-reaching environmental consequences. Corrosion can cause leaks and spills, leading to soil and water pollution. This can harm wildlife and ecosystems, and can also affect human health if contaminated water or soil is consumed.
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