Design, construction, and validation for in-situ water layer thickness determination during accelerated corrosion testing

Abstract

A sensor to determine water layer (WL) thickness, ranging from 0−5 mm, in salt-spray testing is presented. WL thickness is based on electrical resistivity and sensor design was guided by Finite Element Modeling with validation under known WL thicknesses. WLs were measured in continuous salt spray testing and angle of exposure played the largest role in thicknesses. At angles greater than 20˚ from vertical, semi-periodic run-off decreased WLs up to 80 %. Finally, exposure angle determines if thin-film conditions are achieved, likely influencing corrosion rate and morphology. Allowances for sample angle in testing standards pose a potentially large source of variability.