Use Corrosion Analysis and Testing to Get Ahead of the Problem
Corrosion is an enormous and largely unseen cost to our economy – over $1 trillion a year in the US alone! By accurately identifying and understanding corrosion failures, we can help solve and prevent corrosion in the future. Often the replacement cost may be minimal, but the lost production costs are enormous. We use our experience in corrosion failure analysis to help you save time and money. Our team of corrosion experts will apply decades of experience to help you battle and defeat corrosion through forensic science.
What does it cost and is it worth it?
Our cost for a corrosion failure analysis can range from $1,500 to $10K or more. The cost varies depending on the nature of the failure and the analyses required. In many instances, the value of preventing future failures can be thousands or millions of dollars – in which case it’s worth it. Sometimes, the part that fails may only cost $2, but if the resulting damage is extensive, then it’s worth preventing those parts from failing too! If you aren’t sure, we offer free corrosion consultations to help you figure out if it’s worth it to you.
How is a corrosion failure analyzed?
First, the details of the failure are compiled including the environment, application, and notable details. Then a combination of analytical techniques are used to determine the nature and extent of the corrosion, including:
- Optical and electron microscopy with energy dispersive X-ray spectroscopy
- Optical emission spectroscopy
- Mechanical testing
- Corrosion testing
A corrosion expert then takes that data and determines the root cause of failure, often using resources like the ASM Corrosion Handbook.
What is corrosion testing and failure analysis for?
Corrosion testing involves developing information on the various ways that materials corrode by exposing them at appropriate simulated conditions. Tests on samples can then be extrapolated to determine the likely corrosion rates of different applications. Corrosion testing helps guide the selection of materials, coatings, biocides, inhibitors, and many other parameters that can help appropriately prevent corrosion failures.
Routine testing of each batch is often required for verification of quality standards, especially for corrosion-resistant materials. Many ASTM, NACE, ISO, and other applicable standards exist. Immersion corrosion, abrasion, wear, pitting, crevice corrosion, sour corrosion, hydrogen embrittlement, and many other processes are used, depending on the material and application. The objective is to find and remove bad (susceptible to corrosion) materials before they enter service and can result in a future failure (like the corrosion fatigue cracking shown below).
Corrosion failure analysis is the other side of the spectrum – we look at the reasons why failures occur in operating systems so that we can evaluate how to improve or mitigate future failures. Our experts work with you to understand the root cause and then find an appropriate fix or mitigation strategy. This can be as simple as a coating or change or material, or much more thorough like implementation of a plant-wide mechanical integrity program.