Problems related to corrosion cost commercial and industrial plants billions of dollars each year. The biggest risks come from equipment failures, which can result in damage to capital assets, production loss and downtime, and safety and environmental hazards. Although a variety of means exist to inhibit corrosion, it’s important to identify why corrosion occurs in the first place. Our Corrosion Monitoring and Metallurgy Services group, which is a key element of our Customer Applications Laboratories, provides failure analysis and assessments of pulp mill, paper mill, tissue mill, steam-generating and heat exchanger equipment. Working closely with customers, we provide clear identification of the problem parameters, which leads to more rapid and effective corrosion control and system reliability.
Failure Analysis
Our scientists use a number of techniques to identify high-temperature, corrosion and stress-related failure mechanisms, including material (alloy) identification, microstructural examination, visual and microscopic inspection, physical dimensional analysis, metal hardness testing, deposit or corrosion product analysis, and microphotographic documentation. Pit depth measurements and wall thickness evaluations are also utilized to assess corrosion. We can also analyze deposit mass loading (deposit weight density) to assess the need for chemical cleaning of boilers. On-site inspection and formal presentation of failure investigation reports are available on an as-needed basis.
Corrosion Coupon Analysis
Corrosion test specimens of various metallurgies are provided for use by field sales and applications engineers to monitor conditions and product performance in customers’ systems. Laboratory staff clean and weigh returned coupons to determine corrosion rates and provide photographic documentation of metal condition after system exposure. Pit depth studies and chemical analysis of surface deposits can be provided upon request for troubleshooting system and treatment performance.
Elemental and Compound Analysis
Elemental and compound analysis of thin-layered deposits and corrosion products at the metal interface can provide unique corrosion mechanism assessments. Also, direct access to in-house microbiological, water and deposit analysis laboratories enables a rapid and complete profile of microbiologically influenced corrosion failures.
Key Metallurgical Capabilities
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APPARATUS |
INFORMATION PROVIDED |
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Scanning Electron Microscope-Energy Dispersive X-ray Spectroscopy |
Magnification of surface phenomena, elemental analysis of corrosion products and contaminants, alloy assay, elemental mapping |
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Metallograph |
Magnified view of metal microstructures (up to 1000x) |
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Stereomicroscope |
Macroscopic view of surface phenomena and failed components (up to 63x) |
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Hardness Testers |
Macro hardness (Rockwell A, B, C scales) and micro hardness (Vickers) |
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Digital Camera System |
Photographic documentation |
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Dial Indicator Gauges, Vernier Calipers, Micrometer |
Pit depth analyses, wall thickness and estimated remaining life assessments |
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Cutting, Grinding, Polishing Tools |
Preparation of samples for metallographic analysis |
An Integrated Approach
Effective corrosion control requires an integrated approach. Our field representatives work closely with customers to identify the root cause(s) of equipment failures and to take effective and efficient corrective actions. More importantly, our field team collaborates with our laboratory staff to make recommendations about how to prevent recurring equipment failures and plan for appropriate equipment replacement. Seamless coordination between lab and field, supported by state-of-the-art systems and software, ensures timely transmission of analytical results to field representatives for fast interpretation and problem-solving recommendations.
