Corrosion rate measurements

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Corrosion rate measurement techniques

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Corrosion coupons Electrochemical

Potentiodynamic polarization (Tafel analysis) Linear Polarization Resistance (LPR) Electrochemical Impedance Spectroscopy (EIS) Corrosion potential Electrochemical Noise (EN)

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

Thin Layer Activation (TLA) and Gamma radiography

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image source: Cormon, www.cormon.com

Corrosion rate techniques

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Corrosion coupons
Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

Electrical Resistance (ER) Electrical Field Signature Method (EFSM) Hydrogen monitoring Chemical analyses Microscopy

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

A weighed sample (coupon) of the metal or alloy under consideration is introduced into the process, and removed after a reasonable time interval. The coupon is then cleaned of all corrosion product and is reweighed. Alternatively the coupon surface and or corrosion product is analyzed by using microscopy and/or other analytical techniques. The weight loss is converted to a total thickness loss, or average corrosion rate using proper conversion equations.
image source: Cortest, www.cortest.com 4

Corrosion coupons
Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Electrochemical techniques
Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

various coupon shapes and sizes

eV

+ -

+ -

e-

A CE

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

flush disc coupon holder in high pressure access fitting

image source: Metal Samples, http://www.alspi.com/coupons.htm 5

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

ions WE CE
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Electrochemical polarization
Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Thin layer activation

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

involving large perturbations

Potentiodynamic polarization (Tafel analysis)

involving small perturbations

Linear Polarization Resistance (LPR) Electrochemical Impedance Spectroscopy (EIS)

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

involving no perturbations
Corrosion potential Electrochemical Noise (EN)
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Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

A small section of material is exposed to a high energy beam of charged particles, to produce a radioactive surface layer. For example, a proton beam may be used to produce the radioactive isotope Co-56 within a steel surface. This isotope decays to Fe-56, with the emission of gamma radiation. Loss of metal by corrosion manifests itself as loss of radioactivity up and above natural decay.
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Electrical resistance probes

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

ER probe types
Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

This technique operates by measuring the change in electrical resistance of an corroding metallic element relative to a reference non-corroding element sealed within the probe body. Since temperature changes affect the resistance of both the exposed and protected element equally, measuring the resistance ratio minimizes the influence of changes in the ambient temperature.

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation image source: Metal Samples, http://www.alspi.com/coupons.htm

image source: Cormon, www.cormon.com

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High pressure retrievable ER probe fitting

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Hydrogen permeation monitoring

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

The generation of atomic hydrogen, as part of the cathodic reaction in acidic environments, can be used for corrosion monitoring purposes. Hydrogen monitoring sensors are often attached to the outside walls of vessels and piping.

image source: Metal Samples, http://www.alspi.com/coupons.htm

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image source: IonScience, http://www.ionscience.com/

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Hydrogen permeation monitoring principles

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

Surface analyses: microscopy

Introduction
 Significance and cost of corrosion  Definitions and underlying mechanisms  Forms of corrosion  Corrosion rate measurements

As hydrogen passes through the metallic wall of the vessel it enters a probe chamber attached tightly to the outside wall, leading to:
pressure increase with time within the chamber an electrochemical current resulting from the oxidation of hydrogen under an applied potential a current generated in an external circuit, as hydrogen enters a miniature fuel cell

epoxy iron carbonate film 4-6 m

dense layer

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

Electrochemical thermodynamics Electrochemical kinetics Corrosion rate measurements Various forms of corrosion Corrosion mitigation

steel

porous layer

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SEM image of a cross section of a steel specimen including an iron carbonate film. Exposed for 10 hours at T=80C, pH 6.6, PCO2= 0.54 bar, Fe2+= 250 ppm, v=1 m/s. 14