Quantification Of Corrosion Research Articles

Quantification of Corrosion on Cu Wire Bonding on Ag-Plated Lead Frame in HCl for Automotive Electronic Application

Copper (Cu) wire bonding has been widely used in automotive electronics as an interconnection technology. However, Cu wire bonding faces long-term reliability challenges due to corrosion, particularly when exposed to harsh environments. While the corrosion behavior and mechanisms of bulk-sized Cu metal are well studied, the corrosion behavior of submicron-sized Cu wire bonding in miniaturized components remains unclear. This study investigates the corrosion susceptibility of Cu wire with a 1 mil diameter, bonded to an Ag-plated leadframe in a small-outline transistor (SOT-23) package, commonly used in automotive electronics. The Cu wire bonds were subjected to varying concentrations of hydrochloric acid (HCl), specifically 3 M, 5 M, and 7 M, for exposure durations of 6, 12, and 18 hours. The samples were characterized using a field emission scanning electron microscope to observe the microstructure, and ImageJ software was used to quantify the corrosion of the Cu wire bonds. The findings show that the Cu wire bonding is susceptible to corrosion when exposed to high concentrations of HCl. The corrosion of the microstructure became more severe with increasing HCl concentration and exposure time. The affected area of the Cu wire bonding was 21% after 6 hours of exposure to 3 M HCl, increasing to 100% after 18 hours of exposure to 7 M HCl. This study reveals that the corrosion behavior of Cu wire bonding is a combination of selective and pitting-like corrosion, resulting in localized surface degradation rather than uniform corrosion. These findings provide valuable insights into the corrosion behavior of 1 mil Cu wire bonding in SOT-23 packages under highly corrosive environments.

Nondestructive global corrosion measurement using guided wavefield data

Metallic structures often face degradation, and corrosion ranks among the most prevalent forms of deterioration. Accurate quantification of corrosion is crucial, especially for structures exposed to harsh environmental conditions, such as marine vessels and offshore installations. Because the traditional measurement methods based on scanning by ultrasonic gauge are time-consuming and provide only rough information on the thickness variability, there is a need to develop new robust and accurate diagnostics methods. This paper aims to investigate the corrosion monitoring of metal plates using guided wave propagation. Guided waves propagate within the entire volume of the specimen. If it is undamaged and isotropic, the velocity in all directions is the same, and the spreading wavefront takes a circular shape. The primary assumption presented in this paper is that the potential damage caused by corrosion leads to disturbance of this symmetry. The study shows Bilateral and Rotational Corrosion Symmetry Degree (BCSD and RCSD) functions, demonstrating a consistent decrease in symmetry values with increasing degree of degradation (DoD) caused by the corrosion process. The main aim of the study was to test the possibility of corrosion monitoring by using variable number of sensors comprising the transducer network. Also, the influence of the distance between the sensors affecting the size of the monitored area on the corrosion monitoring procedure was investigated. The paper contains the results of numerical and experimental campaigns conducted for corroded plates characterized by variable DoD and monitored using nine different transducers configurations. It is the first step in developing a novel measurement procedure specially designed for the ship and offshore industry. Therefore, because of the initial stage of the study, the last part of the paper discusses the limitations and drawbacks of the presented wave symmetry-based approach.

A Turn-Off Fluorescent Sensor for Metal Ions Quantifies Corrosion in an Organic Solvent

We demonstrate that the corrosion of AISI 1045 medium carbon steel and pure aluminum can be quantified by the turn-off fluorescent sensor Phen Green-SK (PGSK) in ethanol-based solutions. We first evaluate the dependence of the chelation enhanced quenching of PGSK on iron and aluminum ion concentrations. Subsequently, we apply PGSK to examine the anodic dissolution of metal corrosion. The observed time-dependent PGSK-quenching quantifies the corrosion rates of two metals over 24 h of immersion in ethanol-based solutions. The PGSK-based quantification of corrosion is compared to scanning electron microscopy and electrochemical techniques, including open circuit potential and Tafel extrapolation. The corrosion rates calculated from PGSK-quenching and Tafel extrapolation are in agreement, and both indicate a decrease in corrosion rates over 24 h. Our work shows PGSK can efficiently sense and quantify anodic corrosion reactions at metal interfaces, especially in organic solvents or other non-aqueous environments where the application of electrochemical techniques can be limited by the poor conductivity of the surrounding medium.

Intelligent Method for Corrosion Detection and Quantification in Aircraft Lap Joints Using Pulsed Eddy Current

Nondestructive evaluation using pulsed eddy current (PEC) has remarkable capabilities for the detection and characterization of hidden corrosion in multilayer structures. Previous works proposed maximum peak value, time-to-peak, and time-to-zero crossing of PEC signals for hidden corrosion detection. In practice, there are two important noise sources: probe liftoff and interlayer gap. These noise sources disable the aforementioned components in defect detection and classification. This paper delivers a new intelligent method for detection and classification of corrosion defects in two-layer structures at the presence of gap and liftoff. Application independent component analysis and principal component analysis to PEC signals for features extraction and Fisher’s linear discriminant method for classification provide an automatic material loss characterization in multilayer structures. Comparing the results with conventional methods based on PEC signals shows the importance of post-processing methods in the detection and quantification of corrosion.

Application of hyperspectral imaging for characterization of VOC-induced historical glass corrosion

Hyperspectral imaging (HSI) provides high-resolution recording of the spectral information at every spatial point (pixel) of an object throughout a contiguous range of wavelengths. This paper reports an attempt at exploring the application of HSI in transmittance mode for the identification and quantification of corrosion in transparent historical glass, which is difficult to identify by visual inspection. This was done using model glass samples mimicking historical composition and subjected to artificial ageing in the presence of volatile organic compounds. Hyperspectral images of unaged and aged glass samples were recorded with two cameras covering visible and near infrared (VNIR, 400–1000 nm) and short-wave infrared range (SWIR, 1000–2500 nm) using a custom-made HSI set-up in transmission mode. The HSI data were further processed to classify and visualize corrosion in different ageing environments and ageing periods. The results show that HSI can be employed as a valuable tool to assess glass corrosion at early stages, especially by analysing the SWIR spectral region—which shows the water absorption by the glass matrix due to corrosion.

Effect of Cementious Materials on Corrsion in Carbonated Concrete

Reinforced Concrete(RC) is an world wide used material than any other man made material in construction. Today civil engineers are facing a major issue with corrosion in RC. The usage of cementious material in concrete prevents the economics loss and damage of structure. Under condition of carbonated concrete, the quantification of corrosion is determined by using condition evaluation methods like galvanostatic method. By using cementious substances like Silica Fume(SF), Ground Granulated Blast Furnace Slag (GGBS), the galvanostatic method will catalyze long lasting and sustainable concrete for the assessment of carbonation induced corrosion. This paper mainly reports on the study of Corrosion Assessment in carbonated and non carbonated specimens. This investigation includes four series (one carbonated and three non-carbonated) of cubes and beams in standard sizes. The reinforcement provided with 12mm diameter as main reinforcement and 8mm diameter as vertical stirrups. The proportions includes M30 Grade of concrete with GGBS (50%), Silica Fume(3%, 5%,10%) as a cement replacements along with superplasticizers. The methodology was adopted by conducting various test like flexural strength, compressive strength, corrosion rate, degree of corrosion, carbonation depth. The results found were effective, as flexural strength and compressive strength were increased due to the addition of cementious materials, where as carbonation depth and corrosion rate decreased.

Auxiliary Particle Filter–Based Multisensor Data Fusion for Quantification of Corrosion in Aerostructures

Abstract The identification of structural flaws and subsequent management is significant for health monitoring of aviation structures. Wall thickness loss can occur because of corrosion in exposed aerostructures, thereby reducing the strength of the structure. This may impose prolonged downtimes for repair and replacement activities if not detected at early stages. Eddy current testing (ECT) is a viable technique to detect such anomalies. Fusing multifrequency data produces better results because of complementary features of each contributing mode. Particle filter–based methods have already been proposed to detect and quantify flaw profiles of corrosion damage to an aircraft structure using a multifrequency ECT data fusion technique. However, to address the associated drawbacks, an auxiliary particle filter (APF) method is proposed here. In APF, the proposed importance density is a mixture of the prior state and the latest measurements, yielding focused estimation into a high-likelihood region. Simulation results are presented to demonstrate effectiveness of the proposed technique to quantify damages in aerostructures.

Benchmarking parameters for remote electrochemical corrosion detection and monitoring of offshore wind turbine structures

AbstractThe remote location and position of offshore wind turbine structures severely limits the application of in situ corrosion detection methods such as ultrasonic, acoustic emission, and X‐ray. A real‐time remote sensing (RTRS) technology can be implemented to provide autonomous detection and monitoring, providing exhaustive and detailed information on the corrosion process. Utilizing the concept of Internet of Things (IoT) through the integration with satellite and terrestrial communication network, iWindCr, a technology development project funded by the Innovate UK, aims to design a wireless sensor network (WSN) of smart miniaturized sensors for corrosion detection and monitoring of the offshore wind turbine structures. This paper discusses the rationale and challenges around the iWindCr WSN design, particularly in the development of a miniaturized system and in relation to the provision of power and power consumption. The later has led to the selection and the integration of the electrochemical analysis techniques, namely open circuit potential (OCP) and zero resistance ammeter (ZRA) on the sensor interface system. The verification of these techniques for the corrosion detection sensor has resulted in a database consisting of the corrosion parameter outputs or threshold values of metals specific to offshore wind turbine structures, in this case tower, foundation, and nacelle (gearbox). The database provides end‐users with the benchmark that can be used to detect physical changes during the course of corrosion or passive film damage. These parameters are incorporated in the user interface data analytic software, enabling the quantification of corrosion or film damage.

Kinetics of pipeline steel corrosion studied by Raman spectroscopy-coupled vertical scanning interferometry

The corrosion and degradation of materials, such as pipeline steel, have a strong effect on both the environment and the economy. The quantification of these processes can therefore provide important information needed to manage their impact. In this study, a concept for the characterization and quantification of corrosion is demonstrated on API X70 steel immersed in 3.5 wt.% NaCl solution. Due to the difficulty of quantifying corrosion rates, e.g., through single mean values, a unique system is applied that directly couples Raman spectroscopy with vertical scanning interferometry to assess the physical and chemical aspects of steel corrosion kinetics. Vertical scanning interferometry allows the quantification of the topographical evolution of corrosion product formation and material dissolution in combination with the direct measurements of the respective rates. The Raman spectroscopy provides additional information about the (mineral) phases. Rate variations ranging from uniform corrosion to areas of high pit densities are quantified and analyzed in rate maps and subsequently visualized in rate spectra. The rate distribution is classified into different domains and pitting rates. Thus, a comprehensive quantitative assessment of the characteristic corrosion behavior is discussed.

Laser Triangulation Profilometer for Inner Surface Inspection of 100 millimeters (4") Nominal Diameter

A new axis-symmetrical system was developed for inner surface pipe measurement focused in the Oil & Gas industry, aiming the quantification of corrosion and others inner surface anomalies. The measurement principle, calibration, analysis of the measurement errors and laboratory and field results are described.

A three dimensional approach for tracking cracks in bridges using GPR

Abstract Corrosion associated with reinforcing bars is the most significant contributor to bridge deficiencies. The corrosion is usually caused by moisture and chloride ion exposure. The reinforcing bars are attacked by corrosion and yield expansive corrosion products. These oxidation products occupy a larger volume than the original intact steel and internal expansive stresses lead to cracking and debonding. There are some conventional inspection methods for the detection of the reinforcing bar's corrosion but they can be invasive and destructive, often laborious, and lane closure is required and it is difficult or unreliable for any quantification of corrosion. For these reasons, bridge engineers always prefer more to use the ground penetrating radar (GPR) technique. In this work a novel numerical approach for three dimensional tracking and mapping of cracks in the bridge is proposed. The work starts from some interesting results based on the use of the 3D imaging technique in order to improve the potentiality of the GPR to detect voids, cracks or buried objects. The numerical approach has been tested on data acquired on a bridge by using a pulse GPR system specifically designed for bridge deck and pavement inspection. The equipment integrates two arrays of Ultra Wide Band ground coupled antennas, having a main working frequency of 2 GHz. The two arrays are using antennas arranged with a different polarization. The cracks, associated often to moisture increase and higher values of the dielectric constant, produce a not negligible increase of the signal amplitude. Following this, the algorithm, organized in preprocessing, processing and postprocessing stages, analyzes the signal by comparing the value of the amplitude all over the domain of the radar scan.

Quantification of Corrosion Pitting Under Immersion and Salt Spray Environments on an As-Cast AM60 Magnesium Alloy

An AM60 magnesium alloy was exposed to immersion and cyclical salt spray environments to characterize its corrosion rate. General corrosion, pitting corrosion, and intergranular corrosion rates wer...

MFC-Based Structural Health Monitoring Using a Miniaturized Impedance Measuring Chip for Corrosion Detection

This article presents an experimental study using an active sensing device that consists of a miniaturized impedance-measuring chip (AD5933) and a self-sensing macrofiber composite (MFC) patch to detect corrosion in aluminum structures widely used for aerospace, civil, and mechanical systems. A simple beam structure made from a 6063 T5 aluminum alloy was selected for corrosion-detection testing. Four different corrosion cases with two different locations and two different degrees at each location were artificially inflicted on the beam using hydrochloric (HCI) acid. To identify the degrees and locations of the corrosion, the electromechanical impedance-based damage-detection technique using the proposed active sensing device was investigated. Root-mean-square deviation (RMSD) metric of the real part of the impedances obtained from the MFC patch was selected as a damage-sensitive feature. Experimental results have verified that the proposed approach can be an effective tool for detection and quantification of corrosion in aluminum structures.

Characterization of pitting damage and prediction of remaining fatigue life

Quantification of corrosion and modeling of subsequent fatigue crack growth have been the focus of much intense inquiry in recent years. In previous work, the present authors proposed a crack growth model for this fatigue damage scenario that incorporated recent laboratory observations and built upon the approaches of other researchers. Here this model is extended to establish fatigue life prediction distributions for pre-corroded 2024-T3 aluminum using random cross-sectional plane micrographs as the damage quantification means. First, using automated image analysis, metrics are extracted from these micrographs that are shown to bear relevance to the fatigue performance of the material. Insight was gained by studying this pitting from a number of different perspectives, including analysis of spatial distribution and morphology. Based on the observation that the failure of individual, pre-corroded, fatigue specimens often results from the simultaneous nucleation of several cracks, a life prediction method is presented. Here, multiple crack evolution scenarios are simulated with the understanding that the distribution of lowest resulting lives will be limiting and thus representative of the experimentally observed lives. The resulting life predictions are shown to compare well against experimental values. Model sensitivities are addressed and the merits and limitations of the proposed methodology are discussed.

A methodology for the quantification of corrosion and erosion damage in laboratory, burner rig and plant environments.

A methodology for the quantification of corrosion and erosion damage in laboratory, burner rig and plant environments.

A methodology for the quantification of corrosion and erosion damage in laboratory, burner rig and plant environments

A methodology for the quantification of corrosion and erosion damage in laboratory, burner rig and plant environments

A new computational imaging method for the remote detection and quantification of hidden corrosion

Reliable detection and quantification of metal losses under field conditions present a difficult situation. Currently, no reliable and practical method exists, although there are considerable efforts now directed towards a solution. This paper presents promising early results in detection and quantification of corrosion in lap joint situations using remote acoustic impact Dopplcr (RAID) technology.