Corrosion sensors

• US 5,286,357 A
• Filed: 08/04/1992
• Issued: 02/15/1994
• Est. Priority Date: 08/03/1991
• Status: Expired due to Fees

• Current Assignee: BAE Systems Plc, Capcis March Limited
• Original Assignee: British Aerospace, Inc. (BAE Systems Plc), Capcis March Limited
• Inventors: Cox, William M., Smart, John D.
• Primary Examiner(s): Weisstuch, Aaron
• Application Number:
  US07/924,830
• Time in Patent Office: 560 Days
• Field of Search: 204/153.11, 204/404, 324/71.2, 324/425, 324/448, 324/700
• US Class Current: 205/776
• CPC Class Codes: G01N 17/02 Electrochemical measuring systems for weathering, corrosion or corrosion-protection measurement

Abstract

A corrosion sensor (1), apparatus for detecting corrosion of a surface incorporating the sensor, a structural assembly (1,21) incorporating the sensor and method for detecting corrosion of a surface employing the sensor are provided. The sensor comprises a thin flexible non-conducting substrate (18) for attachment to a surface subject to corrosive influence and an array of at least two thin flexible metallic electrodes (2,3,4) carried on the substrate wherein the electrodes are disposed closely adjacent one another so as to permit the generation of electric current by electrochemical action therebetween upon corrosion of the electrodes.

The apparatus comprises one or more of the corrosion sensors (1) each being attachable to the surface so as to be exposed to the same corrosion conditions as the surface and means (6, 8, 10, 12, 14, 16) for measuring corrosion-induced electrochemical activity between the electrodes to provide an output indicative of the corrosion and the method provides a method of use of the apparatus described.

Claims

1. Apparatus for detecting corrosion of a surface, comprising

at least one corrosion sensor comprising a thin flexible non-conducting substrate and an array of at least two thin flexible metallic electrodes carried on said substrate, wherein said electrodes co-extend closely adjacent one another so as to permit spontaneous generation of electrical signals by electrochemical action between said electrodes upon their corrosion, said at least one sensor being attachable to said surface so as to be exposed to the same corrosive conditions as said surface, and

means for measuring, without the application of any electrical potential to said at least one corrosion sensor, corrosion-induced electrochemical activity between said electrodes to provide an output indicative of the corrosion.

2. Apparatus as in claim 1 wherein said electrodes co-extend closely adjacent one another with a gap therebetween of substantially 0.25 mm.

3. Apparatus as in claim 1 wherein said means for measuring corrosion-induced electrochemical activity between said electrodes includes means for measuring electrochemical coupling current between a first pair of said electrodes, means for measuring electrochemical noise between a second pair of said electrodes, and means to compare said coupling current with said current noise to provide an output indicative of the degree to which corrosion is localized.

4. Apparatus as in claim 3 including means for monitoring electrochemical potential noise between a further pair of said electrodes and means for comparing said electrochemical potential noise with said electrochemical current noise to indicate the overall rate of corrosion.

5. Apparatus as in claim 4 including means to compare said overall rate of corrosion with said degree of localization of corrosion to give an indication of rate of localized corrosion.

6. A structural assembly comprising at least one panel member and at least one corrosion sensor according to claim 1 attached to said at least one panel member, said at least one panel member and at least one corrosion sensor being exposable simultaneously to a common corrosive influence.

7. A method of detecting corrosion of a surface, comprising the steps of

attaching to the surface a corrosion sensor comprising a thin, flexible, non-conducting substrate and an array of at least two thin, flexible, metallic electrodes carried on said substrate, wherein said electrodes co-extend closely adjacent one another so as to permit spontaneous generation of electrical signals by electrochemical action between said electrodes upon their corrosion,

subjecting said sensor and surface to a corrosive influence, and

measuring, without the application of any electrical potential to said corrosion sensor, corrosion-induced electrochemical activity between said electrodes.

8. A method of detecting breakdown of a protective coating applied to a surface subject to corrosive influence, including the steps of

attaching to said surface at least one corrosion sensor comprising a thin, flexible, non-conducting substrate and an array of at least two thin, flexible, metallic electrodes carried on said substrate, wherein said electrodes co-extend closely adjacent one another so as to permit spontaneous generation of electrical signals by electrochemical action between said electrodes upon their corrosion,

applying said protective coating to cover both said surface and said at least one corrosion sensor, and

measuring, without the application of any electrical potential to said corrosion sensor electrodes, corrosion induced electrochemical activity between said electrodes.

9. A method of detecting cracking in a surface of a structure by corrosion measurement, including the steps of

attaching to said surface in a position subject to both the possibility of cracking and to corrosive influence a corrosion sensor comprising a thin, flexible, non-conducting substrate and an array of at least two thin, flexible, metallic electrodes carried on said substrate, wherein said electrodes co-extend closely adjacent one another so as to permit spontaneous generation of electrical signals by electrochemical action between said electrodes upon their corrosion in such a manner that said cracking will break down the insulation of the non-conducting substrate and permit corrosion induced electrochemical activity to take place between said structure and at least one of said electrodes of said corrosion sensor, and

measuring, without the application of any external electrical potential to said substrate of said corrosion sensor by measuring apparatus, corrosion induced electrochemical activity between said structure and at least one of said electrodes.

10. A method of measuring mechanical strain of a structure by comparative corrosion measurement, including the steps of

attaching to a surface of said structure subject to both mechanical strain and corrosive influence a first corrosion sensor comprising a thin, flexible, non-conducting substrate and an array of at least two thin, flexible, metallic electrodes carried on said substrate, wherein said electrodes co-extend closely adjacent one another so as to permit spontaneous generation of electrical signals by electrochemical action between said electrodes upon their corrosion, whereby said first corrosion sensor will be subject to substantially the same mechanical strain and corrosive influence as said surface,

positioning a second said corrosion sensor to be subject to substantially the same corrosive influence as said first corrosion sensor but not to be subject to said mechanical strain,

measuring, without applying any external electrical potential to either of said corrosion sensors, corrosion induced electrochemical activity between said electrodes of each said corrosion sensor, and

comparing the values measured to give an indication of mechanical strain of the structure.

11. A structural assembly comprising

at least one panel member, and

apparatus for detecting corrosion of a surface, including at least one corrosion sensor comprising a thin, flexible, non-conducting substrate for attachment to a surface subject to corrosive influence and an array of at least two thin, flexible, metallic electrodes carried on said substrate, wherein said electrodes co-extend closely adjacent one another so as to permit spontaneous generation of electrical signals by electrochemical action between said electrodes upon their corrosion,

said at least one sensor being attachable to said surface so as to be exposed to the same corrosive conditions as said surface, and

means for measuring, without the application of any electrical potential to said at least one corrosion sensor, corrosion-induced electrochemical activity between said electrodes to provide an output indicative of the corrosion,

said at least one corrosion sensor being attached to said at least one panel member so as to be exposed simultaneously to a common corrosive influence.

12. A structural assembly as in claim 11 wherein said at least one panel member and said at least one corrosion sensor are covered by a common protective coating.

13. A structural assembly as in claim 11 wherein said apparatus for detecting corrosion is electrically connected to said at least one panel member and to said at least one corrosion sensor whereby to measure corrosion induced electrochemical activity between said panel member and at least one electrode of a said corrosion sensor upon insulation breakdown of said non-conductive substrate.