Corrosion Detection Coatings

In the last few decades, various approach have been proposed to detect corrosion including ultrasonic, radiographic, thermal imaging, electromagnetic and electrochemical monitoring. However they require trained personnel, large instruments that has to be transported to the site of corrosion, as well as complicated data interpretation which can sometimes be subjective. Some areas are also not accessible because of complex geometry of the part. As such, there is an increasing interest in research of smart coatings that can detect corrosion at the earliest. The idea is to put corrosion indicator chemicals along with the paint on metal or metal alloy surface to provide an early warning of corrosion. In this Phase 1 SBIR proposal, we will develop polymers coatings that contain metal selective chemo-sensors. These polymers can be applied by themselves or as a pretreatment layer on metal surface. Early corrosion that generates metal ions will cause the polymer indicator layer to fluoresce, which can be observed using a hand-held UV light. We will apply the polymers as a pretreatment layer on and metal coupons evaluate the capability of corrosion detection using accelerated corrosion tests. The annual cost of corrosion is estimated at $300 billion in USA; for military and civilian aircraft systems the cost is $3 billion and $10 billion respectively. Some of the military and civilian aircraft parts, such as bilge and wheel wells see continuous corrosive environments; maintaining operational capability for such parts is a challenge, both for the military and civilian. Apart from military and commercial aircrafts, such coating will also find various civilian applications such as detection corrosion in bridges, industrial equipment, ships, and industrial structures.