Corrosion expertise: diagnose and improve reliability

Corrosion found on a metal part can have immediate consequences for quality, equipment availability, product compliance, and non-quality costs. Pitting, galvanic corrosion, localized attack, abnormal oxidation, loss of coating thickness, or premature degradation of a surface treatment: each phenomenon requires a rigorous diagnosis. Our corrosion expertise approach makes it possible to identify the mechanisms at work, to characterize deposits, contaminants, or oxidizing agents, and to link surface observations to conditions of use, manufacturing, or storage. The goal is to quickly determine the root cause of the failure, validate the material’s performance, and define relevant corrective actions before industrial-scale production or return to service.

Identifying a corrosion mode relies on cross-referencing several levels of information: the morphology of the attack, the chemical nature of the corrosion products, the presence of precursors, the surface condition, and the metallurgical context. Investigations make it possible to study phenomena such as pitting corrosion, crevice corrosion, galvanic corrosion, or generalized oxidation. Observations using SEM-EDX, optical microscopy, and surface analysis by XPS or XRD help qualify deposits, detect halogens or contaminants, and assess the degree of oxidation. In addition, our expertise on corrosion precursors can be explored further via Corrosion Precursor Analysis Laboratory.

To anticipate corrosion phenomena before market launch or ramp-up, we set up accelerated aging tests and simulations of specific environments. Salt spray, exposure to chlorinated media, acidic or alkaline solutions, seawater, or media containing inhibitors make it possible to objectively compare several materials, coatings, paints, or surface treatments. These tests are used to rank technical solutions, verify the performance of a part, and guide the choice of a more durable material/process pair. Innovative protection approaches can also be put into perspective with the issues described in Nanomaterials Industrial Coatings.

Expert assessments rely on a consistent set of technical resources: FEG-SEM and SEM-EDX for the morphology and composition of surfaces and deposits, FEG-SEM-EDX for in-depth observation, ICP for trace element research, XPS for surface chemistry, XRD for crystal structure, optical microscope for metallographic observations and micrographic cross-sections, hardness tester for comparing failed areas, as well as potentiostat and salt spray equipment for corrosion testing. This complementarity makes it possible to establish a robust diagnosis, from the altered surface to the material’s behavior in its environment.

Our support covers failure analysis, corrosion resistance validation, quality monitoring of materials and processes, as well as R&D support. Investigations rely on multi-scale observations, electrochemical testing, and physico-chemical analysis to understand corrosion from the surface down to the microstructure. We carry out comparative studies of coatings, paints, and surface treatments, simulations of specific environments such as seawater, chlorinated environments, extreme pH conditions, or inhibitor-containing media, as well as accelerated aging campaigns. To explore a related need in more depth, you can also consult our Corrosion Resistance Testing page or our content dedicated to Galvanic Corrosion Pitting Corrosion.

Beyond visual inspection, it is often necessary to verify the metallurgical grade of the part, the uniformity of a surface treatment, or the loss of coating thickness. Checks may include composition determination by ICP, elemental analysis, hardness measurement, micrographic cross-sections, and examination of surface defects such as cracks, irregularities, or wear marks. This approach makes it possible to compare the part against its specifications, validate a manufacturing process, and objectively document the compliance of the delivered product.

Electrochemical tests provide a detailed, quantitative understanding of corrosion behavior. Open circuit potential measurement OCV assesses the spontaneous behavior of a metal in a given medium. LSV makes it possible to estimate the corrosion rate. EIS is particularly useful for detecting defects in protective coatings, assessing their homogeneity, and studying surface phenomena. Galvanic coupling studies, meanwhile, make it possible to analyze interactions between two metallic materials and the risks of differential corrosion within an assembly.

The value of this approach is not only analytical. It is designed to provide conclusions that can be directly used by quality, methods, production, materials, and R&D teams: likely origin of the corrosion, validation or rejection of a grade, influence of a surface treatment, effect of an assembly, prioritization of causes, and recommendations for corrective actions. You therefore have objective evidence to secure a supplier, adjust a process, requalify a coating, or define a complementary test plan.

Calling on a specialist in corrosion expertise means being able to quickly determine the origin of observed corrosion, validate the resistance of materials and processes, and anticipate phenomena before industrialization. Support can cover failure analysis, comparative coating studies, surface treatment qualification, experimental design, quality monitoring, and team training. To launch your project: have a failed part analyzed, compare several coatings, simulate your operating environment, measure the corrosion rate, check the uniformity of a surface treatment.