Electrochemical analysis: identifying and preventing corrosion in the laboratory

Unanticipated corrosion can lead to loss of thickness, coating degradation, reduced performance, or premature part failure. In an industrial context, it is essential to quickly identify the attack mechanism, verify how a material performs in its real environment, and objectively compare several technical solutions. Our support in corrosion analysis helps determine the origin of a failure, validate the resistance of materials and processes, and anticipate aging phenomena before industrialization. Investigations may cover pitting, crevice, galvanic, or general corrosion, including the study of deposits, contaminants, oxidizing agents, and surface conditions.

The choice of tests depends on the material, the coating, the medium, and the industrial objective. Measuring the open circuit potential (OCV) provides an initial reading of the spontaneous behavior of a metal in a given solution. LSV helps quantify the corrosion rate and compare several surface conditions, treatments, or formulations. EIS is particularly relevant for evaluating protective barriers, early defect detection, and monitoring coating changes over time. In the presence of multi-material assemblies, galvanic coupling studies make it possible to anticipate electrochemical incompatibilities.

Interpreting a corrosion phenomenon does not rely solely on electrochemical testing. It also draws on complementary observation and analysis methods: SEM-EDX for the morphology and composition of deposits or corrosion products, optical microscopy for micrographic cross-sections and metallographic examination, ICP for trace element detection, XPS for surface chemistry, and XRD for identifying crystalline structures. These tools make it possible to assess the degree of oxidation, detect precursors such as halogens, deposits, or contamination, and verify the homogeneity of a surface treatment.

Working with a specialized laboratory makes it possible to objectify technical choices before market launch, supplier changes, formulation updates, or process modifications. The tests help verify a part's resistance to corrosion, check coating compliance, measure thickness loss, and monitor the stability of a surface treatment. This approach reduces the risk of in-service failure, non-quality costs, and field returns.

The laboratory carries out dedicated tests in Electrochemical Analysis to characterize the behavior of a metal or coating in a given medium. Open circuit potential (OCV) measurements assess the material's spontaneous behavior. LSV makes it possible to estimate the corrosion rate, notably in mm/year depending on the test conditions. Electrochemical impedance spectroscopy (EIS) is used to detect coating defects, assess their homogeneity, and study interfacial phenomena. Galvanic coupling studies analyze the interactions between two metallic materials and the risks of differential corrosion. These tests can be supplemented by surface observations, chemical analysis, and accelerated aging tests to obtain a complete understanding of the degradation mechanism.

The tests are carried out in representative simulated media: seawater, chlorides, acidic or basic solutions, extreme pH conditions, and media with inhibitors. This simulation capability makes it possible to bring the test closer to real service conditions and obtain results useful for R&D, process qualification, and solution comparison. The electrochemical data can be correlated with observations from Laboratoire Analyse Meb or with material investigations via Laboratoire analysis Met.

Depending on the need, investigations may also include salt spray tests, comparative studies of coatings, paints, and surface treatments, as well as fracture or surface defect analysis. This comprehensive approach is useful for distinguishing a design flaw, a process issue, a material nonconformity, or an incompatibility between the material and the environment. For broader qualification needs, links can also be made with Analyse Inclusion Laboratoire and structured R&D approaches via Laboratoire Agree Cir.

The laboratory supports industrial clients from feasibility studies to failure analysis, with the design of test plans, simulation of specific media, and comparative analysis. This approach is particularly useful for selecting a material, qualifying a paint or treatment, validating corrosion resistance, and documenting a technical file. Additional regulatory or methodological needs can also be integrated with Laboratoire Analyse Iso 21392.

The study begins with an analysis of your needs: part type, material, coating, operating environment, failure history, and expected objective. Based on these elements, a test plan can be developed by combining electrochemical analysis, environment simulation, accelerated aging, and surface analysis. This approach makes it possible to address needs related to understanding, comparison, validation, or prevention. To initiate the project, it is advisable to provide the exposure conditions, any available drawings or specifications, and, if possible, representative samples.