Surface process analysis: resolving adhesion defects and corrosion in the laboratory

An adhesion defect, premature corrosion, delamination, cracking, discoloration, or a coating non-conformity can have multiple causes: surface contamination, insufficient preparation, material/coating incompatibility, treatment heterogeneity, in-service aging, or an aggressive environment. Our Surface Process Analysis approach makes it possible to link the actual condition of the outermost surface, the chemistry of the layers, topography, thickness, and microstructure to the failures observed in production, qualification, or after commissioning. This approach helps manufacturers identify root causes objectively, secure technical choices, and reduce the risk of scrap, customer returns, and line stoppages.

Identifying surface contamination or a chemical anomaly is often decisive when analyzing an adhesion defect. XPS and TOF-SIMS techniques make it possible to characterize the outermost surface, confirm the chemical nature of a treatment, and detect species likely to interfere with bonding or corrosion protection. In addition, the observations and microanalyses carried out via our Laboratoire Analyse Meb help visualize defects, deposits, and local heterogeneities.

corrosion analysis relies on cross-disciplinary expertise combining surface observations, chemical analysis, metallographic cross-sections, and identification of corrosion products. The laboratory can quickly determine the origin of observed corrosion, look for oxidizing or corrosive agents, compare sound and failed areas, and verify the conformity of the metal grade. To further investigate the possible causes of an interfacial defect, it is also useful to consult our content on adhesion issues and surface defects.

The laboratory deploys complementary resources depending on the issue: XPS for surface chemistry, TOF-SIMS for the outermost surface, SEM-EDX and FE-SEM for morphology and composition, optical microscopy for metallographic observations, ICP for trace elements, XRD for phase identification, a roughness tester and AFM for topography, a durometer for area comparisons, C/S, N/O, H elemental analysis for material characterization, as well as X-ray tomography for non-destructive testing. For metallic materials and their failures, our Laboratoire analysis Met page can also complement your reading.

The laboratory supports manufacturers across all sectors in characterizing adhesion defects, confirming the chemical nature of a treatment, checking layer uniformity and thickness, verifying coating conformity, and investigating corrosion analysis from R&D through to production. The investigations combine surface analysis, cross-section observations, electrochemical tests, accelerated aging, and multi-scale expertise to quickly determine the origin of a failure, validate material resistance, and anticipate phenomena before industrialization. This approach applies to metals, coatings, paints, deposits, and assemblies exposed to a wide range of environments.

Cross-section analysis by SEM-EDX and optical microscopy make it possible to verify that treatment layers are continuous, homogeneous, and free from delamination. Thickness measurement, morphology observation, topographical analysis, roughness, and study of the substrate/coating interface provide concrete data to qualify a process. Depending on the need, these results can be supplemented by AFM, XRD, X-ray tomography for non-destructive testing, and accelerated aging tests to link structure and performance.

Corrosion performance can be assessed through electrochemical tests and accelerated aging. Measurements of open circuit potential (OCV), corrosion rate (LSV), electrochemical impedance (EIS), and galvanic coupling make it possible to compare materials, coatings, and assemblies in specific environments. Salt spray tests or tests in simulated environments, such as chlorides, extreme pH, seawater, or inhibitor solutions, help anticipate risks before industrialization and validate processes.

Beyond the analytical findings, the goal is to provide actionable conclusions for production, quality, and R&D: validation of cleaning processes, optimization of surface treatments, comparative studies of coatings and paints, quality monitoring, material/process compliance, aging studies, and comprehensive design of experiments. The laboratory is COFRAC-accredited for part of its activities and can support qualification procedures, contradictory expertise, resolution of non-conformities, or assistance in selecting a surface treatment.

Working with the laboratory means benefiting from independent expertise to understand a failure, confirm a root-cause hypothesis, and guide corrective actions. The approach combines responsiveness, advanced analysis, performance testing, materials expertise, and technical support to reduce scrap, improve the reliability of surface treatments, and speed up decision-making. Depending on your needs, support can range from one-off analysis to process validation, and even tailored training for your teams.