The present disclosure provides a high-flux sensor suitable for corrosion big data monitoring and a method of manufacturing the same. The sensor includes a first metal sheet, a second metal sheet and an insulating sheet therebetween. The two metal sheets are laminated. The metal sheets and the insulating sheet form a test piece group. A through hole is drilled in the test piece group.

A system, an apparatus and a method for simulating and assessing a damaged corrosion film in a pipe segment for pitting corrosion potential under field conditions, including variations in cathode to anode ratios. The apparatus has an anode case that holds a working electrode, a first body portion attachable to one end of the pipe segment, and a second body portion attachable to another end of the pipe segment, the first and second body portions defining a corrosion simulation cell. The anode case can be contained within the corrosion simulation cell, and the working electrode can include a test matrix.

A method and apparatus of detecting incipient corrosion on surfaces of an object. The method comprising immersing the object into an electrolyte, and detecting by electrochemical techniques the presence of corrosion on the surfaces of the object based on current originating from redox reaction of iron.

A reference electrode includes a metal body, a lead disposed within the metal body, an insulator disposed between the lead and the metal body, the insulator including a ceramic material, and a porous metal chamber coupled to the metal body, the lead extending into the porous metal chamber. The porous metal chamber is configured to maintain an electrolyte solution within the porous metal chamber to establish a redox couple with the lead.

Hundreds of thousands of concrete bridges and hundreds of billions of tons of concrete require characterization with time for corrosion. Accordingly, protocols for rapid testing and improved field characterization systems that automatically triangulate electrical resistivity and half-cell corrosion potential measurements would be beneficial allowing discrete/periodic mapping of a structure to be performed as well as addressing testing for asphalt covered concrete. Further, it is the low frequency impedance of rebar in concrete that correlates to corrosion state but these are normally time consuming vulnerable to noise. Hence, it would be beneficial to provide a means of making low frequency electrical resistivity measurements rapidly. Further, prior art techniques for electrical rebar measurements require electrical connection be made to the rebar which increases measurement complexity/disruption/repair/cost even when no corrosion is identified. Beneficially a method of determining the state of a rebar without electrical contact is taught.

Provided is a measurement method for measuring a size of expansion of a surface treatment film occurred in a coated metal material that includes a metal base and the surface treatment film provided on the metal base. The measurement method includes the steps of disposing a water-containing material to be in contact with the expansion and an electrode to be in contact with the water-containing material, and electrically connecting between the electrode and the metal base with an external circuit; applying, with the external circuit, a constant voltage between the electrode and the metal base, as a cathode and an anode, respectively, and measuring a current value flowing therebetween; and calculating a size of the expansion, based on the current value measured and a correlation between the current value and the size of the expansion, the correlation being determined on an exploratory basis in advance.

A method for measuring a thickness of a deposit layer on a metal or alloy substrate using an X-ray fluorescence (XRF) spectrometer, where the deposit layer includes scale deposits or corrosion products. As part of the method, an elemental composition of the deposit layer or the metal or alloy substrate is measured using the XRF spectrometer. The thickness of the deposit layer is obtained from the elemental composition using a calibration relationship between deposit layer thicknesses and corresponding elemental compositions of the deposit layer or the metal/alloy substrate. The method can be applied to determine the rate of deposit layer formation and evaluate the effectiveness of a treatment.

A corrosion resistance tester for a coated metal material including a surface treatment film on a metal substrate includes: a container placed on the surface treatment film, and having a bottom surface in contact with the surface treatment film, the container including a plurality of water-containing electrolyte material holders that open through the bottom surface; the water-containing electrolyte material contained in each of the water-containing electrolyte material holders of the container, and being in contact with an associated one of a plurality of separate measurement target portions of the surface treatment film; a plurality of electrodes being each in contact with the water-containing electrolyte material contained in an associated one of the water-containing electrolyte material holders; an external circuit connecting the electrodes together; and a conduction means configured to conduct electricity to the metal substrate through the electrodes and the external circuit.

A repair method for self-detecting and self-healing of corrosion defects in metals can achieve self-detecting and self-healing repair of an initial corrosion defect and be used to repair a micron-level corrosion defect. Furthermore, the self-detecting and self-healing repair method can be used to effectively repair an initial corrosion defect in a large-sized high-precision structural component, thus effectively improving the service safety of the high-precision metal structural component and prolonging the service life of the same.

A sensor system is installed adjacent to the buried or submerged metallic pipelines using a plurality of sensors and transceivers. The sensor system monitors the pipeline for external corrosion control and recommends maintenance and repair at specific locations in the pipeline where external corrosion has occurred. The sensor system automatically receives periodic or continuous measurements through the plurality of sensors. The various sensors at various locations adjacent to the pipelines detect irregularities in the received sensor data at specific locations of the pipeline. The sensor data are stored in the system database and can analyzed to be used for monitoring and for transmitting repair alerts. The sensor system according to the present disclosure provides a reliable and an accurate assessment of the external corrosions of the pipelines. The sensor system further obviates the need of personnel walking along the pipelines to detect corrosion.