Matergenics performs standard and non-standard corrosion tests for evaluation of materials for underground, atmospheric , chemical process and aerospace applications. Quality control tests are also performed. Specific attention is given to scientific and technical concepts behind accelerated corrosion tests and their relationship with real-world aerospace service environments.


Corrosion Testing of Materials

Several requirements must be addressed in the usefulness of accelerated testing in life expectancy determination.

A primary requirement is that the corrosion failure mechanism(s) should be the same as those which occur under normal service conditions. Otherwise, the test lacks validity with regard to simulating the service environment.

A second key requirement is that sufficient scientific understanding of the failure mechanism should be available so that the test data can be analyzed and interpreted in a physically meaningful way.

We are well aware of shortcomings of the American Society for Testing and Materials’ ASTM B117-11 salt spray (fog) test as a predictor of the service lifetime of aerospace materials. We are one of the few laboratories that perform ASTM B845 mixed flowing gas environmental pollutant test to simulate the actual atmospheric exposure conditions of aerospace components. Our electrochemical AC/DC testing along with ASTM G71-81 galvanic corrosion testing and ASTM G44-99(2005) alternate immersion testing will provide the client high confidence test procedures to estimate and determine the corrosion behavior of aerospace and aircraft materials in given environment.

Accelerated Corrosion Testing:  

Accelerated corrosion testing is used for various purposes to simulate the conditions that a product will be exposed to in actual service conditions.  As the performance of a product is often linked to the service environment where it is placed, it is of the utmost importance that products are manufactured taking the various aspects of inclement weather and corrosive environmental conditions into consideration.

The use of laboratory exposure testing provides manufactures and suppliers with an advanced understanding of the limitations of the components used in manufactured products prior to the purchase and or inclusion of these products in a larger component of final product.  This forward thinking approach not only limits the time, energy and income spent of inferior products but also limits the risk of losing market position, clientele and customers due to inferior product performance.  In a nutshell, accelerated corrosion testing is used to induce corrosion and failure in a relatively short period of time when compared to corrosion produced as a natural occurrence.  This provides the means for decision makers to tweak, redesign using alternate materials, or eliminate a particular supplier with inferior products altogether.

Corrosion experts at Matergenics are NACE Certified in corrosion, coating, cathodic protection, and materials selection with more than 30 years of experience in testing, inspection and mitigation of corrosion. We have installed numerous corrosion control and corrosion monitoring systems for industrial, commercial and residential applications.

high confidence test procedures

We use electrochemical AC/DC testing along with ASTM G71-81 galvanic corrosion testing and ASTM G44-99(2005) alternate immersion testing

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Laboratory Equipment and Testing

  • Scanning electron microscope (SEM)
  • Elemental dispersive x-ray (EDS)
  • X-ray Diffraction (XRD)
  • Fourier transformer infrared (FTIR)
  • Optical light microscopy with digitized imagining (OLM)
  • Positive Material identification (PMI) / X-Ray Fluorescence (XRF)
  • Electrochemical Impedance Spectroscopy (EIS)
  • Electrochemical Corrosion Testing
  • Chemical analysis
  • Mechanical testing
  • Hardness / Microhardness Testing
  • Environmental testing
  • Mixed flow gas chamber
  • Salt spray testing
  • QUV testing
  • Immersion testing
  • MFG and Cabinet Testing

Our recent field investigations have included major condenser failures in West Virginia, failure of paint/galvanizing coatings on galvanized structural members of the Aloha stadium in Hawaii, analysis of failures of salt-water plumbing on a luxury yacht in Antigua, failures of cathodic protection systems in a submarine tunnel in Chesapeake Bay, failures of polyuria roofing systems in a university in south Florida, corrosion of lead-coated copper roofing in a government building in Illinois, and analysis of the incipient failure of concrete in the dome of the State Capitol building in Salt Lake City, Utah.

Standard and customized tests:

  • General Exposure Tests
  • Stress Corrosion Cracking Tests
  • Environmentally-Assisted Corrosion Tests
  • Treated Wood Corrosion Tests
  • Cabinet Test
  • Electrochemical Test ASTM G61, ASTM G71..
  • Materials Selection Testing
  • CDT , Cathodic Disbondment Tests
  • Hydrogen Diffusion Tetss

Standard ASTM and NACE tests include: 

  • ASTM G102: Calculation of Corrosion Rates and Related Information from Electrochemical Measurements
  • ASTM G44: Exposure of Metals and Alloys by Alternate Immersion in Neutral 3.5 % Sodium Chloride Solution
  • ASTM B117, ASTM G85, Salt Spray tets
  • ASTM G148: Evaluation of Hydrogen Uptake, Permeation, and Transport in Metals by an Electrochemical Technique
  • ASTM G31: Immersion Corrosion Testing of Metals
  • ASTM G5, G59, G61: Potentiodynamic Polarization tests
  • Corrosion Testing and Corrosion Control in Electrical, Telecom and Utility Manholes
  • ASTM G108: Electrochemical Reactivation (EPR) for Detecting Sensitization of AISI Type 304 and 304L Stainless Steels
  • ASTM D2247, D4585: Humidity Chamber Tests
  • ASTM G129: Slow Strain Rate Testing to Evaluate the Susceptibility of Metallic Materials to Environmentally Assisted Cracking
  • ASTM B827: Mixed Flowing Gas (MFG) Environmental Tests
  • ASTM G50: Atmospheric Corrosion Tests on Metals
  • ASTM F1624: Hydrogen Embrittlement Test
  • ASTM G106: Verification of Algorithm and Equipment for Impedance Measurements

Corrosion Experts

Matergenics Engineers are NACE Certified in corrosion, coating, cathodic protection, and materials selection with more than 30 years of experience in testing, inspection and mitigation of corrosion.

Cabinet and Environmental Chamber Testing

An environmental test chamber artificially replicates conditions which machinery, materials, devices or components might be exposed to. It is also used to accelerate the effects of exposure to the environment, sometimes at conditions not actually expected.

Chamber testing involves testing and exposing products to various environmental conditions in a controlled setting. Climatic Chamber testing and Thermal Shock testing are part of chamber testing. Climatic Chamber testing is a broad category of ways to simulate climate or excessive ambient conditions exposure for a product or a material under laboratory-controlled yet accelerated conditions. On the other hand, Thermal Shock testing is used to simulate how materials will react when exposed to changes in extreme climatic conditions, such as going from extremely cold to extremely hot conditions in a very short period of time (usually only few seconds).

These conditions may include:

  • Temperatures and  humidity
  • Immersion or alternate immersion
  • Salt Spray ASTM B117 and G85
  • Acid rain
  • Moisture or wetness and humidity
  • Mixed Flow Gas
  • Electrochemical
  • Cyclic corrosion testing ASTM G85
  • UV Damage and exposure to sun,

Manufactured samples, specimens, or components are placed inside the chamber and subjected to one or more of these environmental parameters to determine reliability or measure after-effects such as corrosion. In the case of machinery such as internal combustion engines, byproducts such as emissions are monitored.

Many of our chambers and laboratory set ups are set at a certain set of conditions. Others can be programmed to cycle through specified sequences of conditions.

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