Electrochemical analysis to prevent corrosion in space components

In space applications, the corrosion of space parts can compromise the reliability of an assembly, the performance of a coating, electrical continuity, or the service life of a component. Manufacturers must anticipate the effects of controlled atmospheres, storage phases, humid, saline, or harsh ground environments, as well as the interactions between alloys, surface treatments, and galvanic couples. An electrochemical analysis approach makes it possible to identify degradation mechanisms, compare several material solutions, and validate a technical choice before industrial-scale production. This approach is useful in aerospace, space, defense, energy, or any sector handling high-specification metal parts. To broaden the approach by area of use, also see our Sector Activity page.

The expertise makes it possible to analyze a component showing pitting, crevice corrosion, galvanic corrosion, advanced oxidation, thickness loss, cracking, or fracture. Fractographic observation characterizes the failure mode, highlights characteristic clues, and compares sound and failed areas through microstructure, hardness, and composition. The analysis can also verify the metal grade against a customer specification and search for oxidizing or corrosive agents at the origin of the failure.

Electrochemical tests include open-circuit potential (OCV) measurement, corrosion rate determination by LSV, electrochemical impedance spectroscopy (EIS) to assess the uniformity and defects of a protective coating, as well as galvanic coupling studies between assembled materials. These tests can be carried out in specific media simulating seawater, extreme pH, the presence of inhibitors, or other representative service environments. Salt spray tests and accelerated aging protocols complete the performance assessment.

Before industrialization, expertise makes it possible to compare several alloys, paints, coatings, or surface treatments in order to select the most robust solution. In production, it helps control process uniformity, verify material/process compliance, and document drift before it generates major nonconformities. This approach reduces technical risk, improves component durability, and makes it easier to justify material choices to clients and principals.

Support is based on cross-disciplinary expertise combining electrochemical testing, surface characterization, chemical analysis, and microstructural observations. The goal is to quickly determine the origin of observed corrosion, validate the resistance of materials and processes, and anticipate corrosion phenomena before production ramp-up. Investigations may combine OCV open-circuit potential measurement, corrosion rate by LSV, electrochemical impedance spectroscopy (EIS), galvanic coupling studies, salt spray testing, deposit analysis, coating thickness checks, and cross-section observations. This multi-technique expertise approach is part of R&D, qualification, quality control, and failure analysis processes. To explore this field further, discover Electrochemical Analysis and Characterization and the capabilities of a Metallurgical Analysis Laboratory.

Surface defects are studied to identify wear, irregularities, cracks, delamination, coating heterogeneity, or adhesion defects. Cross-section analysis make it possible to confirm the uniformity of surface treatments and measure the remaining coating thickness. Surface chemical analysis specifies the nature of layers, deposits, or contamination. For advanced investigations of interfaces and multilayers, FIB ToF-SIMS analysis can complement the interpretation.

Interpretation relies on complementary resources: field-emission SEM (FEG-SEM), SEM-EDX, and SEM-FIB-EDX for morphology, fracture surfaces, and local composition; optical microscopy for micrographic sections and metallographic observations; XPS for surface chemistry; ICP for trace element analysis; XRD for crystal structure; hardness testing and elemental analysis to confirm the material condition. This combination makes it possible to move from defect observation to understanding the corrosion mechanism.

The value of an expert laboratory lies in its ability to cross-reference electrochemical data with surface chemistry, microstructure, deposits, and fracture observations. The results are therefore interpreted in light of the real industrial context: assembly, treatment, environment, aging history, and level of requirement. This integrated reading makes it possible to provide operational conclusions: confirm a root cause, prioritize contributing factors, and guide additional testing or corrective actions.

To start a study, it is necessary to define the part’s function, the materials involved, the surface treatments, the exposure environment, and the failure mode observed or feared. It is then possible to commission comparative tests, characterize surfaces and deposits, assess the corrosion rate, verify coating uniformity, and confirm the source of degradation. The approach may be aimed either at a one-off expert assessment or at a test program for R&D or qualification.