Devices and Test Equipment for Liquid and Vapor Wire Exposure Testing

Abstract

The test device (1) includes a scaffold (30, 230) for supporting the conductive wires. The scaffold is disposed in a housing in which liquid and vapor phases of a fluid are provided, so that a first conductive wire extends into the liquid and a second conductive wire remains in the vapor throughout the test. The scaffold may include a plurality of lower support members and a plurality of upper wire support members, each of which includes a plurality of routing supports (51, 53, 61, 63, 251, 253, 261, 263) and wraps around a respective one of the test wires (8, 9). The device is capable of simultaneously performing measurements on the test wires.

Description

[Background technology]

[0001] The present disclosure and exemplary embodiments described herein relate to testing apparatus, methods and systems, specifically to a scaffold suitable for simultaneously measuring wire corrosion in the liquid and gas phases of a fluid, as well as testing devices and apparatus incorporating the scaffold.

[0002] Traditional methods for monitoring corrosion processes and mechanisms in real time can be time consuming and difficult to interpret, especially when evaluation at multiple temperatures is desired.

[0003] Corrosion is a very complex and chaotic multi-component scientific problem, and the most common way to assess the amount of corrosion caused by lubricant additives on copper surfaces is to use the standard ASTM D130 test method, where copper test coupons, immersed in the lubricant for several hours, are compared to a standard set, and a rating is given based on color. The coupon or strip test can be expanded to include additional information, such as the end of test concentration of copper in solution or mass loss / gain information, but these types of tests alone do not provide details on the chemical kinetics or time dependence of the corrosion process. There are several issues with the suitability of this test, the first issue is that it was originally designed to test the corrosivity of petroleum products (base oils) to copper. The second issue is that the test only gives a visual rating and does not provide information on what is happening at the surface. Such information is useful in assessing the impact of petroleum formularies on metal corrosion. The purpose of performing corrosion tests is to provide information on the lubricant compatibility and corrosion performance of the lubricant in use, and one way to achieve this is to use a long duration high temperature corrosion test. This approach is only appropriate if the same corrosion processes occur at higher temperatures and are not subject to new or competing reactions that only persist at higher temperatures.

[0004] According to one previous design, the wire support design utilizes a series of pegs extending from a central shaft to wrap a nominal length of wire, e.g., one meter, for testing in the liquid rather than vapor in the container. The single wire peg design requires the wire to be zig-zag placed between the pegs, which allows for the required length of wire within the space of the container. The single wire peg wire support is immersed in the test fluid inside the container, holding the length of wire below the fluid, thereby allowing corrosion to occur on the wire. The test wire is terminated by soldering the ends of the wire to gold plated connector contacts located in the two top holes in the head of the single wire support. It is time consuming to route the wire to prepare the sample for testing.

[0005] There remains a need for a scaffolding and device that allows for conductive wires to be supported in the same housing, facilitating the generation of real-time corrosion test results in the solution and the vapor phase of the solution. Summary of the Invention [Means for solving the problem]

[0006] According to one aspect of the exemplary embodiment, the scaffold includes a plurality of spaced apart lower support members, each of the plurality of lower support members including a plurality of first routing supports for spacing apart a plurality of turns of an associated first test wire when the associated first test wire is wound around the plurality of lower support members. The scaffold further includes a plurality of spaced apart upper support members, each of the plurality of upper support members including a plurality of second routing supports for spacing apart a plurality of turns of an associated second test wire when the associated second test wire is wound around the plurality of upper support members. The closure member provides a connection between an end of the first test wire and a respective associated outer conductor, and provides a connection between an end of the second test wire and a respective associated outer conductor. The closure member, or an optional upper cross member attached thereto, is attached to a first end of each of the plurality of upper support members. The second cross member is longitudinally spaced from the closure member. A second cross member is attached to a first end of each of the plurality of lower support members and to a second end of each of the plurality of upper support members to laterally space the plurality of lower support members and the plurality of upper support members.

[0007] In various embodiments, the scaffolding thus described may further include a third cross member longitudinally spaced from the closure member by the second cross member, the third cross member attached to a second end of each of the plurality of lower support members.

[0008] At least one of the first routing supports may include an opening for receiving the first test wire therethrough. The first and second sets of routing supports may include notches. The first and second routing supports may be longitudinally spaced apart on the respective upper and lower support members. Each of the lower support members may include at least three, or at least four, or at least five of the first routing supports, and each of the upper support members may include at least three, or at least four, or at least five of the second routing supports.

[0009] The closure member may have a tapered rim.

[0010] Each of the lower support members may include an opening for carrying a first test wire therethrough. The upper and lower support members may be parallel to one another. There may be at least four, at least five, or at least six upper support members. There may be at least four, at least five, or at least six lower support members. The upper support members may be arcuately offset from the lower support members. The second cross member may include arcuately spaced slots, with second ends of the upper support members being received in alternate ones of the slots and first ends of the lower support members being received in alternate remaining ones of the slots.

[0011] The second cross member may include at least one groove for guiding the first test wire from the closure member to the lower support member and back to the closure member.

[0012] The closure member may include holes for receiving the first and second temperature sensors.

[0013] The plurality of lower support members, the plurality of upper support members, the closure member, the second lateral member, and the first lateral member, when present, may all be formed of plastic.

[0014] The plurality of lower support members, the plurality of upper support members, the closure member, the second lateral member, and the first lateral member, if present, may be formed by one of 3D printing and injection molding.

[0015] At least one of the length of each wire turn defined by the plurality of lower support members and the number of first routing supports is different from at least one of the length of each wire turn defined by the plurality of upper support members and the number of second routing supports, providing equal routing lengths for the first and second test wires.

[0016] A plurality of spaced apart lower support members may be longitudinally aligned with a central axis of the scaffold, and a plurality of spaced apart upper support members may be longitudinally aligned with the central axis.

[0017] In another embodiment, an assembly includes a scaffold as described in any one or more of the above embodiments, and further includes first and second test wires, wherein the first and second test wires are electrically conductive.

[0018] The first and second test wires may be of equal length and / or equal diameter.

[0019] One or more of the first and second test wires may be formed of copper or an alloy thereof.

[0020] In another embodiment, a test device includes a scaffold as described in any one or more of the embodiments above, or an assembly as described in any one or more of the embodiments above. The test device further includes a housing shaped to receive the scaffold, wherein a closure member of the scaffold closes an upper end of the housing to form a container for holding an associated liquid in contact with the first test wire such that a gas phase of the liquid contacts the second test wire.

[0021] In various embodiments, the testing device may further include a solution phase temperature sensor positioned within the housing to measure the temperature of the liquid and / or a vapor phase temperature sensor positioned within the housing to measure the temperature of the vapor. The solution phase temperature sensor and the vapor phase temperature sensor may be connected to the external conductor via a closure member.

[0022] The testing device may further include a heater configured to heat the liquid within the housing to form a vapor.

[0023] The test device may further include one of a first and a second electrical system. The first electrical system may include a first current source connected across the ends of the first test wires to provide a current through the first test wires, a second current source connected across the ends of the second test wires to provide a current through the second test wires, a first voltmeter connected across the ends of the first test wires to measure a voltage across the first test wires, and a second voltmeter connected across the ends of the second test wires to measure a voltage across the second test wires. The second electrical system may include a first voltage source connected across the ends of the first test wires to generate a voltage across the first test wires, a second voltage source connected across the ends of the second test wires to generate a voltage across the second test wires, a first ammeter connected across the ends of the first test wires to measure a current across the first test wires, and a second ammeter connected across the ends of the second test wires to measure a current across the second test wires.

[0024] The test device may further include at least one of a first and a second electrode, where the first electrode is immersed in the solution and the second electrode is immersed in the vapor, a voltage or current source, if present, connected to the first electrode and passing a current between the first electrode and the first wire, and a voltage or current source, if present, connected to the second electrode and passing a current between the second electrode and the second wire.

[0025] The test apparatus may include a test device according to any of the above aspects and a monitoring system that receives signals from the first voltmeter and the second voltmeter or from the first ammeter and the second ammeter and calculates and outputs information based thereon.

[0026] In various embodiments, the monitoring system may include a data acquisition component that acquires at least one of a voltage and a current through the test wires over time, a data analysis component that processes the acquired at least one of the voltage and current multiple times and calculates information based thereon, and an output component that outputs the information. The information may include a measurement of corrosion of each of the test wires. The measurement of corrosion of each of the test wires may include a calculated change in diameter or radius of the test wire. The monitoring system may be in communication with temperature sensors disposed in the liquid and vapor, respectively. The information may include a measurement of corrosion as a function of temperature of the liquid.

[0027] According to another aspect of the exemplary embodiment, a method includes wrapping a first test wire around a plurality of spaced apart lower support members of a scaffold, such as the scaffold of any of the above aspects. A second test wire is wrapped around a plurality of spaced apart upper support members of the scaffold. A test fluid is introduced into a housing. The scaffold and the first and second test wires are inserted into the housing such that the second test wire is spaced apart from a liquid phase of the test fluid and a closure member closes an open end of the housing. The test fluid in the housing is heated to produce a gas phase that contacts the second test wire. An electrical characteristic of the first and second test wires that changes over time is measured. Information is determined based on the change in the electrical characteristic of each wire.

[0028] In various embodiments, the measurement of the electrical properties of the first and second test wires over time includes measuring one of a current and a voltage. The information may include a measurement of corrosion of the test wires. The method may further include providing a solution phase temperature sensor in contact with the solution phase, providing a vapor phase temperature sensor in contact with the vapor phase, and calculating a temperature dependence of the measurement of corrosion. In the method, the test fluid may include a lubricant, a coolant, and / or a corrosion inhibitor. At least one of the test wires may be formed of copper or a copper alloy. The test wires may be of equal length and / or equal diameter. The lengths of the test wires may each have a length of at least 50 cm, or up to 500 cm. The test wires may each have a diameter of at least 0.05 mm, or up to 5 mm.

[0029] According to another aspect of the exemplary embodiment, the test device includes a scaffold for supporting associated first and second test wires, and a housing shaped to receive the scaffold, wherein a closure member of the scaffold closes an upper end of the housing to form a container for holding an associated liquid in contact with the first test wire such that a gas phase of the liquid contacts only the second test wire.

[0030] In various embodiments, the testing device may further include a solution phase temperature sensor positioned within the housing to measure the temperature of the liquid and / or a vapor phase temperature sensor positioned within the housing to measure the temperature of the vapor. The solution phase and vapor phase temperature sensors may each be connected to a respective external conductor via a closure member. The testing device may further include a heater configured to heat the liquid in the housing to form a vapor.

[0031] The test device may further include one of a first and a second electrical system, the first electrical system including a first current source connected across an end of the first test wire to supply current through the first test wire, a second current source connected across an end of the second test wire to supply current through the second test wire, a first voltage measuring device connected across an end of the first test wire to measure a voltage across the first test wire, and a second voltage measuring device connected across an end of the second test wire to measure a voltage across the second test wire. The second electrical system may include a first voltage source connected across the ends of the first test wires to generate a voltage across the first test wires, a second voltage source connected across the ends of the second test wires to generate a voltage across the second test wires, a first current measuring device connected across the ends of the first test wires to measure a current across the first test wires, and a second current measuring device connected across the ends of the second test wires to measure a current across the second test wires.

[0032] The test device may further include first and second electrodes, one of the electrodes immersed in the solution, and a voltage or current source connected to the electrodes and passing a current between the electrode and the wire. The present invention provides, for example, the following items. (Item 1) A scaffold (30, 230), a plurality of spaced apart lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235), each of the plurality of lower support members including a plurality of first routing supports (53, 56, 253, 256) for spacing apart a plurality of turns (51) of an associated first test wire (8) when the first test wire is wound around the plurality of lower support members; a plurality of spaced apart upper support members (41, 42, 43, 44, 45, 341, 342, 343, 344, 345), each of the plurality of upper support members including a plurality of second routing supports (61, 63, 261, 263) for spacing apart a plurality of turns (52) of an associated second test wire (9) when the second test wire is wound around the plurality of upper support members; a closure member (64, 270) providing a connection between an end of the first test wire (8) and its associated outer conductor (100, 101) and providing a connection between an end of the second test wire (9) and its associated outer conductor (102, 103); the closure member (64, 270), or an upper cross member (76) attached thereto, the closure member (64, 270), or an upper cross member (76) attached thereto, being attached to a first end (48, 348) of each of the plurality of upper support members; a second lateral member (74, 274) spaced longitudinally from the closure member (64, 270), the second lateral member (74, 274) attached to a first end (38, 238) of each of the plurality of lower support members and attached to a second end (47, 347) of each of the plurality of upper support members, laterally spacing the plurality of lower support members and the plurality of upper support members. (Item 2) 2. The scaffold (30, 230) of claim 1, further comprising a third cross member (72, 272) longitudinally spaced from the closure member (64, 270) by the second cross member (74, 274), the third cross member (72, 272) being attached to a second end (37, 237) of each of the plurality of lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235). (Item 3) 3. The scaffold (30, 230) according to item 1 or 2, wherein at least one of the first routing supports (53, 56, 253, 256) on the lower support member (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235) includes an opening (300) for receiving the first test wire (8) therethrough. (Item 4) 2. The scaffolding (30, 230) of any one of the preceding items, wherein the first and second routing supports (53, 56, 61, 63, 253, 256, 261, 263) comprise a notch. (Item 5) 2. The scaffolding (30, 230) of any one of the preceding items, wherein the first and second routing supports (53, 56, 61, 63, 253, 256, 261, 263) are longitudinally spaced apart on the respective upper and lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235). (Item 6) 2. The scaffold (30, 230) according to any one of the preceding items, wherein each of the lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235) comprises at least three, or at least four, or at least five of the first routing supports (53, 56, 253, 256), and each of the upper support members comprises at least three, or at least four, or at least five of the second routing supports (61, 63, 261, 263). (Item 7) 2. The scaffold (30, 230) of any one of the preceding items, wherein each of the lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235) includes an opening (300) for conveying the first test wire (8) therethrough. (Item 8) 2. The scaffold (30, 230) of any one of the preceding claims, wherein the closure member (64, 270) comprises a tapered rim (114, 278). (Item 9) 2. The scaffolding (30, 230) according to any one of the preceding items, wherein the upper and lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235) are parallel to each other. (Item 10) 2. The scaffold (30, 230) of any one of the preceding items, wherein there are at least four, or at least five, or at least six upper support members (41, 42, 43, 44, 45, 341, 342, 343, 344, 345). (Item 11) 2. The scaffolding (30, 230) according to any one of the preceding items, wherein there are at least four, or at least five, or at least six lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235). (Item 12) 2. The scaffolding (230) according to any one of the preceding claims, wherein the upper support members (341, 342, 343, 344, 345) are offset in an arc from the lower support members (231, 232, 233, 234, 235). (Item 13) 2. The scaffolding (230) of any one of the preceding items, wherein the second cross member (274) includes arcuately spaced slots (282), the second ends (347) of the upper support members (341, 342, 343, 344, 345) being received in alternate ones of the slots, and the first ends (238) of the lower support members (231, 232, 233, 234, 235) being received in remaining alternate ones of the slots. (Item 14) 2. The scaffold (230) of any one of the preceding claims, wherein the second cross member (274) comprises at least one groove (299, 303) for guiding the first test wire (8) from the closure member (64, 270) to the lower support member (231, 232, 233, 234, 235) and back to the closure member. (Item 15) 2. The scaffold (30, 230) of any one of the preceding items, wherein the closure member (64, 270) comprises holes (95, 96, 295, 296) for receiving first and second temperature sensors (104, 105, 297, 298). (Item 16) 2. The scaffold (30, 230) of any one of the preceding items, wherein the plurality of lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235), the plurality of upper support members (41, 42, 43, 44, 45, 341, 342, 343, 344, 345), the closure member (64, 270), second lateral member (74, 274), and first lateral member (72), if present, are formed of plastic. (Item 17) 2. The scaffold (30, 230) of any one of the preceding items, wherein the plurality of lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235), the plurality of upper support members (41, 42, 43, 44, 45, 341, 342, 343, 344, 345), the closure member (64, 270), the second lateral member (74, 274), and the first lateral member (76), if present, are formed by one of 3D printing and injection molding. (Item 18) 2. The scaffold (30, 230) according to any one of the preceding items, wherein at least one of the length of each wire turn defined by the plurality of lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235) and the number of the first routing supports (51, 53, 251, 253) is different from at least one of the length of each wire turn defined by the plurality of upper support members (41, 42, 43, 44, 45, 341, 342, 343, 344, 345) and the number of the second routing supports (61, 63, 261, 263) to provide equal routing lengths for the first and second test wires (8, 9). (Item 19) 2. The scaffold (30, 230) of any one of the preceding claims, wherein the plurality of spaced apart lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235) are longitudinally aligned with a central axis of the scaffold, and the plurality of spaced apart upper support members (41, 42, 43, 44, 45, 341, 342, 343, 344, 345) are longitudinally aligned with the central axis. (Item 20) A scaffold (30, 230) according to any one of the preceding items; and said first and second test wires (8, 9), said first and second test wires being electrically conductive. (Item 21) 21. The assembly (140, 240) of item 20, wherein the first and second test wires (8, 9) are of equal length. (Item 22) 22. The assembly (140, 240) according to item 20 or 21, wherein the first and second test wires (8, 9) are of equal diameter. (Item 23) 23. The assembly (140, 240) of any one of items 20 to 22, wherein at least one of the first and second test wires (8, 9) is formed of copper or an alloy thereof. (Item 24) A test device (1), A scaffold (30, 230) according to any one of items 1 to 19 or an assembly (140, 240) according to any one of items 20 to 23, A testing device (1), comprising: a housing (110, 210) shaped to receive the scaffold, wherein the closure member (64, 270) of the scaffold closes an upper end of the housing to form a container (2) for holding an associated liquid (4) in contact with the first test wire (8) such that a gas phase of the liquid contacts the second test wire (9). (Item 25) a solution phase temperature sensor (104, 297) positioned within the housing to measure the temperature of the liquid; 25. The testing device (1) of claim 24, further comprising a vapor phase temperature sensor (105, 298) positioned within the housing to measure the temperature of the vapor. (Item 26) 26. The solution and steam wire corrosion test device (1) according to item 25, wherein the solution phase temperature sensor (104, 297) and the gas phase temperature sensor (105, 298) are connected to the outer conductor (101, 102, 103, 104) via the closure member (64, 270). (Item 27) 27. The testing device (1) of any one of items 24 to 26, further comprising a heater (112) configured to heat the liquid within the housing to form the vapor. (Item 28) and one of a first and a second electrical system, the first electrical system comprising: a first current source (12) connected across an end of the first test wire (8) to supply a current through the first test wire; a second current source (18) connected across an end of the second test wire (9) to supply a current through the second test wire; a first voltmeter (10) connected across an end of the first test wire (8) to measure the voltage across the first test wire; a second voltmeter (16) connected across an end of the second test wire (9) to measure the voltage across the second test wire; the second electrical system: a first voltage source connected across an end of the first test wire (8) to generate a voltage across the first test wire; a second voltage source connected across an end of the second test wire to generate a voltage across the second test wire; a first ammeter connected across an end of the first test wire (8) to measure the current across the first test wire; 28. The test device (1) of any one of items 24 to 27, comprising: a second ammeter connected across an end of the second test wire (9) to measure the current across the second test wire. (Item 29) 29. The test device (1) according to any one of items 24 to 28, further comprising at least one of first and second electrodes (402, 404), the first electrode being immersed in the solution and the second electrode being immersed in the vapor; a voltage or current source (410), if present, connected to the first electrode and causing a current to flow between the first electrode and the first wire; and a voltage or current source (412), if present, connected to the second electrode and causing a current to flow between the second electrode and the second wire. (Item 30) 30. A test apparatus comprising the test device (1) according to any one of items 24 to 29, further comprising a monitoring system (20) that receives signals from the first voltmeter (10) and the second voltmeter (16) or from the first ammeter and the second ammeter, and calculates and outputs information (22) based thereon. (Item 31) The monitoring system (20), a data acquisition component (24) that acquires at least one of a voltage and a current through the test wire over time; a data analysis component (26) for processing the obtained at least one of the voltage and the current multiple times and calculating the information (22) based thereon; Item 31. The test apparatus of item 30, comprising: an output component (27) for outputting the information. (Item 32) Item 32. The test apparatus of item 31, wherein the information (22) includes a measurement value of the corrosion of each of the test wires (8, 9). (Item 33) Item 33. The test apparatus of item 32, wherein the measurement of the corrosion of each of the test wires (8, 9) comprises a calculated change in diameter or radius of the test wire. (Item 34) 34. The testing apparatus according to any one of items 31 to 33, wherein the monitoring system (20) is in communication with temperature sensors (104, 105, 297, 298) provided in the liquid and the vapor, respectively. (Item 35) 35. The testing apparatus of any one of claims 31 to 34, wherein the information (22) comprises a measurement of corrosion as a function of temperature of the liquid. (Item 36) wrapping a first test wire (8) around a plurality of spaced apart lower support members (31, 32, 33, 34, 35, 36, 231, 232, 233, 234, 235) of a scaffold (30, 230); wrapping a second test wire (9) around a plurality of spaced apart upper support members (41, 42, 43, 44, 45, 341, 342, 343, 344, 345) of said scaffold; Introducing a test fluid into the housing (110, 210); inserting the scaffold and the first and second test wires into the housing such that the second test wire (9) is spaced from the liquid phase (4) of the test fluid and the closure member (64, 270) closes an open end of the housing; heating the test fluid in the housing to produce a gas phase (6) in contact with the second test wire (9); Measuring electrical characteristics of the first and second test wires over time; and and determining information (22) based on the change in the electrical property of each wire. (Item 37) 37. The method of claim 36, wherein the measurement of the electrical property of the first and second test wires (8, 9) over time comprises one of a current and a voltage, the other of the current and voltage being controlled. (Item 38) 38. The method of claim 36 or 37, wherein the information (22) includes a measurement of the corrosion of the test wires (8, 9). (Item 39) providing a solution phase temperature sensor (104, 297) in contact with said liquid phase; providing a gas phase temperature sensor (105, 298) in contact with the gas phase; 39. The method according to any one of items 36 to 38, further comprising calculating a temperature dependence of the corrosion measurement. (Item 40) 40. The method of any one of items 36 to 39, wherein the test fluid comprises a lubricant. (Item 41) 41. The method of any one of items 36 to 40, wherein the test fluid comprises a coolant. (Item 42) 42. The method according to any one of items 36 to 41, wherein the test fluid comprises a corrosion inhibitor. (Item 43) 43. The method according to any one of claims 36 to 42, wherein at least one of the test wires (8, 9) is made of copper or a copper alloy. (Item 44) 44. The method according to any one of items 36 to 43, wherein the test wires (8, 9) are of equal length and equal diameter. (Item 45) 45. The method according to any one of items 36 to 44, wherein the test wires (8, 9) each have a length of at least 50 cm, or at most 500 cm. (Item 46) 46. ​​The method according to any one of items 36 to 45, wherein the test wires (8, 9) each have a diameter of at least 0.05 mm, or at most 5 mm. (Item 47) A test device (1), a scaffold (30, 230) for supporting associated first and second test wires (8, 9); A testing device (1), comprising: a housing (110, 210) shaped to receive the scaffold, wherein a closure member (64, 270) of the scaffold closes an upper end of the housing to form a container (2) for holding an associated liquid (4) in contact with the first test wire (8) such that the gas phase of the liquid contacts only the second test wire (9). (Item 48) a solution phase temperature sensor (104, 297) positioned within the housing to measure the temperature of the liquid; Item 48. The testing device (1) of item 47, further comprising a vapor phase temperature sensor (105, 298) positioned within the housing to measure a temperature of the vapor. (Item 49) Item 49. The solution and steam wire corrosion test device (1) according to item 48, wherein the solution phase temperature sensor (104, 297) and the gas phase temperature sensor (105, 298) are connected to the outer conductor (101, 102, 103, 104) via the closure member (64, 270). (Item 50) 50. The testing device (1) of claim 48 or 49, further comprising a heater (112) configured to heat the liquid within the housing to form the vapor. (Item 51) and one of a first and a second electrical system, the first electrical system comprising: a first current source (12) connected across an end of the first test wire (8) to supply a current through the first test wire; a second current source (18) connected across an end of the second test wire (9) to supply a current through the second test wire; a first voltmeter (10) connected across an end of the first test wire (8) to measure the voltage across the first test wire; a second voltmeter (16) connected across an end of the second test wire (9) to measure the voltage across the second test wire; the second electrical system: a first voltage source connected across an end of the first test wire (8) to generate a voltage across the first test wire; a second voltage source connected across an end of the second test wire to generate a voltage across the second test wire; a first ammeter connected across an end of the first test wire (8) to measure the current across the first test wire; 54. The test device (1) of any one of items 48 to 53, comprising: a second ammeter connected across an end of the second test wire (9) to measure the current across the second test wire. (Item 52) A test device (1), first and second electrodes (402, 404), the first electrode immersed in the solution and the second electrode immersed in the vapor; a voltage or current source (410) connected to the first electrode and for applying a current between the first electrode and the first wire; 52. The test device (1) of any one of items 48 to 51, further comprising: a voltage or current source (412) connected to the second electrode and passing a current between the second electrode and the second wire. [Brief description of the drawings]

[0033] [Figure 1] FIG. 1 is an electrical schematic diagram of a test apparatus including a solution and steam wire corrosion test device according to one exemplary embodiment. [Diagram 2] FIG. 2 is a first perspective view of a first embodiment of a scaffold for the solution and vapor phase wire corrosion testing device of FIG. 1 according to one exemplary embodiment. [Diagram 3] FIG. 3 is a second perspective view of the scaffold of FIG. 2. [Figure 4] FIG. 3 is a front view of the scaffold of FIG. 2. [Diagram 5] FIG. 3 is a top view of the scaffold of FIG. 2. [Figure 6] FIG. 3 is a third perspective view of the scaffold of FIG. 2. [Figure 7] FIG. 3 is a fourth perspective view of the scaffold of FIG. 2 . [Figure 8]FIG. 3 is an exemplary dimensional drawing of the scaffold of FIG. 2, with dimensions showing the calculated routing lengths of the solution space wires and vapor space wires. [Figure 9] FIG. 3 is an exemplary dimensional drawing of the scaffold of FIG. 2, with dimensions showing the calculated routing lengths of the solution space wires and vapor space wires. [Figure 10] 2 is a perspective cross-sectional view of one embodiment of the corrosion testing device of FIG. 1 including a first assembly of the scaffold of FIG. 2 having a first test wire routed and wrapped around it, a second test wire routed and wrapped around it, as well as a housing, a solution space temperature sensor, and a vapor space temperature sensor. [Figure 11] FIG. 11 is a perspective top view of the corrosion test device of FIG. [Figure 12] 10 is a front view of a second embodiment of a scaffold assembly suitable for injection molding, supporting first and second test wires according to another exemplary embodiment suitable for use in the testing apparatus of FIG. 1. FIG. [Figure 13] FIG. 13 is a first perspective view of the scaffold of FIG. [Figure 14] FIG. 13 is a second perspective view of the scaffold of FIG. [Figure 15] FIG. 13 is a perspective view of the assembly of FIG. 12. [Figure 16] FIG. 13 is a second perspective view of the assembly of FIG. 12. [Figure 17] FIG. 13 is a front view of the scaffold of FIG. 12 having solution space temperature sensors and vapor space temperature sensors according to an exemplary embodiment of the present disclosure. [Figure 18] FIG. 13 is a dimensional drawing of the scaffold of FIG. 12, with dimensions showing the calculated wire routing length of the solution space and the calculated wire routing length of the vapor space. [Figure 19] FIG. 13 is a dimensional drawing of the scaffold of FIG. 12, with dimensions showing the calculated wire routing length of the solution space and the calculated wire routing length of the vapor space. [Figure 20] FIG. 13 is a perspective cross-sectional view of a solution and vapor phase wire corrosion test device with exemplary dimensions, including a housing, the scaffold of FIG. 12, wrapped wires, routing of the solution space wires through the lid, and routing of the vapor space wires through the lid. [Figure 21] FIG. 1 is an electrical schematic diagram of a test apparatus including a solution and steam wire corrosion test device according to another exemplary embodiment. [Figure 22] 2 is a flow chart showing a method that may be performed in the test apparatus of FIG. 1; [Diagram 23] 3 is a flow chart illustrating a portion of the method of FIG. 2 that may be performed in the monitoring system of FIG. 1. [Figure 24] 1 is an example plot of radius reduction in nm (representing corrosion) versus time of a solution space wire in solution and gas phase wire corrosion tests according to an example embodiment. [Diagram 25] 25 is an example plot of radius loss in nm (representing corrosion) versus time for the vapor space wire in the solution and vapor phase wire corrosion tests of FIG. 24. [Figure 26] 1 is an example of an Arrhenius plot for solution and gas phase wire corrosion testing according to an illustrative embodiment. [Figure 27] 1 is an example of an Arrhenius plot for solution and gas phase wire corrosion testing according to an illustrative embodiment. [Figure 28] 1 is an example of an output report for a Wire Corrosion test. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Aspects of the exemplary embodiments relate to a scaffold, a test device including the scaffold, a test apparatus or "system" including the device, and a method that can be used to generate real-time corrosion test results simultaneously for conductive wires supported in the solution and vapor phases of a fluid, respectively. An exemplary test device is a wire corrosion test device that integrates solution space wire supports and vapor space wire supports in a single scaffold within a common housing, e.g., a container such as a beaker, that receives the fluid and the scaffold. The disclosed wire corrosion test device provides for both solution and vapor space wire corrosion tests to be evaluated at the same time, i.e., simultaneously, within the same housing.

[0035] Referring to FIG. 1, an electrical schematic of a test apparatus according to one exemplary embodiment is shown. The test apparatus includes a test device 1, such as a solution and vapor wire corrosion test device, including a sealed vessel 2, such as a beaker or other container. The vessel 2 holds a test fluid, such as a lubricant, in liquid (solution) form 4 in a solution space 5 and in vapor (gas) form 6 in a vapor space 7 of the vessel above the solution space 5. The vapor 6 is in contact with the liquid 4 at the surface of the liquid and is at least partially derived from the liquid. A first conductive test wire 8 (solution test wire) is at least partially suspended in the liquid 4. A second conductive test wire 9 (vapor test wire) is suspended in the vapor 6 but not in the liquid 4. The test wires 8, 9 are formed from a conductive material, such as copper (e.g., at least 95% copper by weight) or an alloy thereof. Other conductive materials, such as silver, titanium, gold, nickel, platinum, zirconium, niobium, or tantalum, alloys thereof, may alternatively or additionally be used for one or both of the wires. Each wire may have a uniform diameter along the length of the wire. In the illustrated embodiment, both wires are formed of the same material and have the same diameter (e.g., the diameter of the first test wire 8 is within ±5% of the diameter of the second test wire 9). Having wires 8, 9 of the same known length and diameter simplifies corrosion measurements.

[0036] In other embodiments, wires made of different materials and / or lengths and / or diameters can be used. Using wires 8, 9 of dissimilar metals allows the wires to act as electrodes (cathode and anode, or vice versa). Which wire is the cathode depends on the experimental conditions. This configuration allows the influence of the electrolysis process by the current flowing through the fluid between the wires to be investigated.

[0037] In the illustrated embodiment, two wires are used, but in other embodiments, fewer or more than two wires may be used in the test, such as two (or more) first test wires 8 and / or two (or more) second test wires 9. The test wires 8, 9 may each have a length of at least 50 cm, or up to 500 cm, e.g., about 100 cm. The test wires 8, 9 may each have a diameter of at least 0.05 mm, or up to 5 mm.

[0038] The exemplary test apparatus includes an electrical system 15 that measures an electrical characteristic of the test wires. In the illustrated embodiment, the electrical characteristic, such as the voltage across the first test wire 8, is detected by a first voltage measurement device, such as a first voltmeter 10. A first current source, such as a DC or AC source 12, supplies current to the first test wire 8. The voltage across the second test wire 9 is detected by a second (or the same) voltage measurement device, such as a second voltmeter 16. A second current source, such as a DC or AC source 18, supplies current to the second test wire 9. In some embodiments, relay controls 17, 19 may be used to switch the wires 8, 9 between power and measurement states.

[0039] In some embodiments, the first test wire 8 is completely immersed in the solution 4. This may be accomplished by replacing the portion of the wire 4 that extends into the vapor space with a larger gauge wire or a shielded (e.g., coated) wire (not shown).

[0040] The test apparatus further includes a monitoring system 20 that receives electrical signals (e.g., measured voltages) from the voltmeters 10, 16 during the course of the test and processes the signals to generate and output information 22. In one embodiment, the information 22 is related to changes in diameter of the test wires 8, 9 during the course of the test due to corrosion. The length and diameter of the test wires 8, 9 may be selected to provide electrical signals that can be encompassed by the monitoring system 20. The illustrated monitoring system 20 includes a data acquisition component 24 that acquires the electrical signals and a data analysis component 26 that processes the acquired signals to generate information 22. The information 22 may be output by an output device 27, for example, stored in a local or remote memory, for example a suitable database 28, or other data structure, output to a display, or otherwise output.

[0041] In one embodiment, the lubricant tested in the device 1 is a composition suitable for lubricating a machine, such as a vehicle engine or transmission. An example of this type of lubricant includes, for example, a base oil of lubricating viscosity as the bulk of the lubricant, and one or more additives, such as detergents, viscosity improvers, corrosion inhibitors, pour point depressants, antiwear agents, etc. The corrosion of the test wires 8, 9 in the lubricant liquid and gas phases 4, 6 of the wire corrosion test device 1 is determined over time by the monitoring system 20 and can be used to assess the suitability of a given lubricant for use in a machine, such as a vehicle engine or transmission system, operating at a temperature where the lubricant liquid and gas phases may exist. Changes in additives can be assessed to determine whether a reduction in corrosion rate can be achieved. Similarly, changes in the material of a machine component can be assessed to determine whether it is more suitable to withstand corrosion by a given lubricant.

[0042] In another embodiment, the fluid tested in device 1 is a cooling liquid suitable for use to cool a heat generating device. In another embodiment, the fluid tested in device 1 is an aqueous solution, such as a solution containing one or more dissolved salts, such as sodium chloride. In one embodiment, the fluid tested in device 1 is a liquid suitable for use in a battery, such as battery acid.

[0043] 2-11, the test wires 8, 9 may be supported on a common support structure ("scaffold") 30. The scaffold 30 includes a plurality of lower support members, such as three, four, five, or six or eight lower support members 31, 32, 33, 34, 35, 36 (six lower support members shown), connected via first and second ends 37, 38 to form a solution space wire support 39, and a plurality of upper support members, such as three, four, five, or six or eight upper support members 41, 42, 43, 44, 45 (five upper support members shown), connected via respective first and second ends 47, 48 to form a vapor space wire support 49. The solution and vapor space wire supports 39, 49 are connected to one another. In one embodiment, pairs of upper and lower support members, such as support members 32 and 42, are connected, e.g., formed as a single piece. In other embodiments, the support members are indirectly connected. The lower and upper support members each extend longitudinally, for example, parallel to the cylindrical axis Y of the scaffold 30 (FIG. 6). The scaffold 30 may be formed in whole or in part by 3D printing or injection molding, and may be formed, for example, of plastic or other non-conductive material.

[0044] The illustrated support members are generally cylindrical between their respective opposing ends 39, 40, 47, 49, although other shapes are contemplated that provide a minimum area of ​​contact with the test wires. The support members may be formed from an electrically insulating material such as plastic, glass, or ceramic, or from a mixture or combination of such materials. The lower support members 31, 32, 33, 34, 35, 36 and the upper support members 41, 42, 43, 44, 45 are spaced apart from one another to define a gap 50 between the support members. The gap 50 allows test fluid to circulate around the test wires and maximize the exposed surface area of ​​the test wires 8, 9.

[0045] The routing supports formed in or on each of the upper and lower support members support and space a plurality of turns 51, 52, etc. of the test wire 8, 9, such as at least three, or at least four, or at least five complete turns, each complete turn circling an entire lower or upper support member. In one embodiment, the test wire 8, 9 may be supported in a set of spaced apart notches in each of the respective lower and upper support members to maintain the turns 51, 52 of the wire out of electrical contact with one another. For example, the routing supports may include a set of solution wire notches 53, 56, etc. defined in the lower support member supporting the first test wire 8 and a set of vapor wire notches 61, 63, etc. defined in the upper support member supporting the second test wire 9 (FIG. 4). In another embodiment (not shown), the routing supports include projections extending laterally outward from the lower and upper support members.

[0046] The exemplary scaffold includes or is connected to a closure member 64, such as a lid that seals the open end of the container 2. The routing length l of each wire 8, 9 (the length of each wire supported by the scaffold from the lid 64, around the support member, and back to the lid) can be made equal by having a different number of turns 51, 52 of each wire (e.g., by providing a different number of notches on the upper and lower support members). Additionally or alternatively, the length of each turn can be different, for example, by spacing the upper support member apart to provide a larger diameter for each turn 52. By equal routing lengths, it is meant that the routing lengths vary by 5% or less, 1% or less, or 0.1% or less.

[0047] The illustrated scaffold 30 includes a closure member or lid 64 that functions to close the top of the vessel 2. A lower cross member ("hub") 72, a middle cross member ("hub") 74, and an upper cross member ("hub") 76 function to space the upper and lower support members in an arc and connect the solution and vapor space wire supports 39, 49 (FIGS. 2 and 3). The lower cross member 72 and the middle cross member 74 are spaced longitudinally from one another and generally perpendicular to the lower support members 31, 32, 33, 34, 35, 36. The middle cross member 74 and the upper cross member 76 are spaced longitudinally from one another and generally perpendicular to the upper support members 41, 42, 43, 44, 45. The upper cross member 76 may be threaded or otherwise connected to the lid 64, for example, by a central member 77.

[0048] As shown in Figures 3 and 4, solution wire supports ("posts") 78 extend upwardly from lower cross-member 72, and vapor wire supports ("posts") 80 extend downwardly from upper cross-member 76 to support the respective wires as they enter through lid 64.

[0049] As shown in Figures 8 and 9, the sets of notches 53, 56, 61, 63 in the vertical support members 31, 32, 33, 34, 35, 36 and 41, 42, 43, 44, 45 provide a fixed length (approximate diameter) for each turn of the respective wire, which may be, for example, 50-100 mm, e.g., 60-70 mm. Each set of notches may include 2-10 notches, such as 4 or 5 notches, which cooperate to allow for a (near) equal number of turns of each wire 51, 53 while keeping the turns of the wire sufficiently spaced apart to minimize electrical contact and the possibility of electric field interference. In the example scaffold, there are 5 notches in each set 61, 63 in each of the upper support members, the notches being vertically spaced 2.5 mm apart, and there are 4 notches in each set 53, 56 in the lower support members. In this embodiment, the fixed routing diameter provided by the upper notch is smaller than the fixed routing diameter of the lower notch so that the length of each wire is approximately equal (wire length = 2πr + 2l, where r is the radius provided by the notch and l is the length from the notch to the respective connector of the lid 64). For example, five notches with a routing diameter of 62 mm spaced 20 mm from the connector in the lid provide support for the second test wire 9 with a length of 1013 mm, and four notches with a routing diameter of 64.8 mm spaced 99 mm from the connector in the lid provide support for the first test wire 8 with a length of 1011 mm. This assumes that each wire 8, 9 is tensioned sufficiently to prevent sagging. Meanwhile, the scaffolding can be configured to support wires of equal length (e.g., within ±10 mm or ±5 mm, or ±1% or less or ±0.5% or less of length difference). Having wires of the same length, as here, provides easier calculation of the wire resistance (or impedance, in the case of an AC voltage or current source). In other embodiments, the first and second test wires 8, 9 may be of different lengths.

[0050] As shown in Figures 5, 6, and 10, the lid 64 includes one or more feedthrough holes 91, 92, 93, 94, which allow electrical connections to be made with the respective ends of the test wires 8, 9 and their respective outer conductors 101, 102, 103, 104. In particular, the feedthrough holes 91, 92 provide a connection between the wire 8 in the solution space 5 and the first power supply 12 and the first voltmeter 10. The feedthrough holes 93, 94 provide a connection between the wire 9 in the vapor space and the second power supply 18 and the second voltmeter 16. The holes may be fitted with push-in connectors that allow for easy connection and disconnection between the test wires 8, 9 and the respective power supplies and voltmeters. Additional holes 95, 96 may serve as electrical feedthroughs for connections 97, 98 to sensors, such as temperature sensors 104, 105 that extend into the liquid and vapor phases, respectively. The temperature sensors 104, 105 may be RTD temperature sensors. The exemplary lid 64 includes a tapered rim 114 to enable the lid to fit snugly within the top of the housing 110 to form the container 2 .

[0051] 10 and 11, a routed and coiled first test wire 8, i.e., solution space wire, and a routed and wrapped second test wire 9, i.e., vapor space wire, are shown within a vessel 2 mounted on a scaffold 30. A first pair of outer conductors 100, 101 connect the ends of the solution phase wire 8 to a first power supply 12 and a first voltmeter 10. A second pair of outer conductors 106, 107 connect the ends of the vapor phase wire 9 to a second power supply 18 and a second voltmeter 16.

[0052] As shown in FIGS. 1 and 10, the test device 1 may include a solution space temperature sensor 104 positioned to measure the temperature of the solution in the solution space 5 and a vapor space temperature sensor 105 positioned to measure the temperature of the vapor in the vapor space 7. The sensors 104, 105 are disposed within the housing 110 of the vessel 2 and are supported, for example, by the scaffolding 30 and / or the lid 64. The sensors 104, 105 provide a temperature signal to the data acquisition device 24. For example, push-in connectors connect the sensors 104, 105 to external wires 106, 107 that are connected to the data acquisition device. In an exemplary embodiment, the connection is made through the lid 64, but in other embodiments, the connection may be made through the cylindrical sidewall of the housing 110 of the vessel 2. The fluid in the test device 1 may be heated by a heater 112, such as an oil bath, glove box, or the like, which may heat the vessel 2 externally. A single heater 112 may be large enough to heat multiple devices 1 simultaneously. Alternatively, an internal heater immersed in the liquid and / or vapor may be used. The heater 112 may be under the control of the monitoring system 20. The bulk fluid temperature ranges of the solution and vapor phases may be the same or different and may range from 20°C to 300°C. The temperature of the surface of the wires 8, 9 may be significantly higher than the surrounding fluids 4, 6 due to resistive heating. In some embodiments, cooling of the surrounding fluid may be used to limit the wire temperature to a suitable range.

[0053] In combination, the scaffold 30 and wires 8, 9 form an assembly 140 that can be easily inserted into the housing 110, for example, as a single unit.

[0054] 12-18, there is shown another embodiment of a scaffold 230 suitable for use in the testing apparatus of Figure 1. Scaffold 230 may be configured similarly to scaffold 30, except as noted.

[0055] As shown in Figures 13 and 14, scaffold 30 includes a plurality of lower support members, such as three, four, five, or six or eight lower support members 231, 232, 233, 234, 235 (five lower support members shown) that define solution space wire supports 239, and a plurality of upper support members, such as three, four, five, or six or eight upper support members 341, 342, 343, 344, 345 (five upper support members shown) that define vapor space wire supports 349. The illustrated support members are curved and have a width greater than their thickness, although cylindrical support members are also contemplated. The support members may be formed from an electrically insulating / non-conductive material, such as plastic (e.g., PTFE), glass, or ceramic, or from a mixture or combination of such materials. The lower support members are spaced apart from one another to define gaps 250 between the support members. The lower and upper support members each extend longitudinally and parallel (e.g., within ±5° of each other). In the illustrated embodiment, the upper support members are equally spaced around the cross member 274 at 72° intervals, and the lower support members are equally spaced around the cross member 272 at 72° intervals. However, the lower support members are offset 36° from the upper support members so that each lower support member is midway between two adjacent upper support members. The scaffold 230 may be formed in whole or in part by 3D printing or injection molding, and may be formed, for example, of plastic or other non-conductive materials. In one embodiment, the scaffold is modeled in 3D using SOLIDWORKS and 3D printed using SLS (selective laser sintering) technology in nylon.

[0056] The test wires 8, 9 may be supported in a set of spaced apart notches (or other routing supports) in each of the respective lower and upper support members to keep the wire coils out of electrical contact. For example, a set of solution wire (first) notches 253, 256 etc. in the outer surface of the lower support member support the first test wire 8, and a set of vapor wire notches 261, 263 etc. in the outer surface of the upper support member support the second test wire 9 (FIG. 15).

[0057] As shown in Figures 12-14, the scaffold 230 includes a closure member, such as a lid 270, which includes a lower cross member 272 and an intermediate cross member 274. In this embodiment, the lid 270 also functions as the upper cross member, although a separate upper cross member (not shown) can alternatively be used, as in the embodiment of Figure 10. The lid 270 functions to close the top of the container 2. The cross members 272, 274 and the lid 270 function to space the upper and lower support members in an arc. In combination, the scaffold 230 and wires 8, 9 form an assembly 240 (Figure 12), which can be inserted into the container housing 110.

[0058] As shown in FIG. 13, the lid includes a circular base member 276 shaped to be received on the top of the container and a tapered rim 278 extending upwardly and outwardly from the base member. The base member 276 defines (five) arcuately spaced slots 280, one for receiving each of the upper support members. The upper end 348 of the upper support member includes a snap-in connector 281 that is received through the slot 280 of the lid 270 for, e.g., removably attaching the support member to the lid. The lower end of the upper support member extends upwardly from the middle cross member 274. The upper end 238 of the lower support member includes a similar snap-in connector that is received through a respective slot 282 of the middle cross member 274 for, e.g., removably attaching the lower support member to the middle cross member 274. The lower end 237 of the lower support member extends upwardly from the lower cross member 272. The lower cross member 272 may include similar arcuately spaced slots 284 so that the middle and lower cross members are interchangeable and / or to allow for additional support members. The slots 282, 284 may be formed in a flange 286 that extends laterally outwardly from a generally circular central portion 288 of each cross member 272, 274. In other embodiments, the lower ends of the support members may also be received in respective arcuately spaced slots that are arcuately offset from the slots 282, 284.

[0059] The lid 270 includes one or more feedthrough holes 291, 292, 293, 294, which allow electrical connection to be made with the respective ends of the test wires 8, 9. In particular, the feedthrough holes 291, 292 in the lid base member 276 provide a connection between the wire 8 in the solution space and the first power supply 12 and the first voltmeter 10. The feedthrough holes 293, 294 in the lid base member 276 provide a connection between the wire 9 in the vapor space and the second power supply 18 and the second voltmeter 16. The holes may fit push-in connectors that allow easy connection and disconnection between the test wires 8, 9 and the respective power supplies and voltmeters. Additional holes 295, 296 may serve as electrical feedthroughs for sensors, such as temperature sensors 297, 298, which extend into the liquid and vapor phases, respectively (FIG. 17). The different sizes and / or shapes of the various holes 291, 292, 293, 294, 295, 296 ensure that the user makes the correct connections between the ends of the test wires 8, 9 and the corresponding external wiring 221, 222, 223, 224, etc., via the push-in connectors, and correctly positions the solution and vapor phase temperature sensors 297, 298 (FIG. 14). The connecting wires 221, 222 connect the ends of the solution phase wires 8 to the first power source 12 and the first voltmeter 10. The connecting wires 223, 224 connect the ends of the vapor phase wires 9 to the second power source 18 and the second voltmeter 16. The temperature sensors 297, 298 provide temperature signals to the data acquisition device 24, for example, via the external wiring. In the exemplary embodiment, the connections are made via the lid 270, but in other embodiments, the connections may be made via the housing 210 of the container 2.

[0060] As shown in FIG. 15, the first test wire 8 is guided by a first groove 299 in the middle cross member 274 adjacent one of the slots 282 and passes through an opening 300 in one of the vertical support members 234. The wire is then wound around the lower support member, supported by the longitudinally spaced notches. As shown in FIG. 16, the wire 8 then passes through an opening 302 in another of the support members 233 and is guided to the lid 270 by a second groove 303 in the middle cross member 274 adjacent a different one of the slots 282. A similar opening may be provided in the upper support member to guide the second test wire 9. In another embodiment, the spaced holes 304 in the cross member may be used as a feedthrough to carry the wire 8. For ease of use, the upper and lower support members may be similarly configured with the same number of openings and notches, so that they may be interchangeable. Additionally, at least the upper and lower ones of the notches in each support member may be shaped as openings so that they can function as either.

[0061] With respect to scaffold 30, scaffold 230 provides a fixed length for each wire 8, 9 (which may be the same or different lengths). Exemplary dimensions (in mm) of scaffold 230 are shown in Figures 18-20. In the example shown in Figure 20, there are 4.2 wraps of wire 8 in the solution space (having an equivalent diameter of 62.5 mm) and 4.8 wraps of wire 9 in the vapor space (having an equivalent diameter of 62.5 mm). The distance from the solution space 5 to the wire wraps to the lid 270 is slightly longer than in the vapor space 7, and therefore the test wires 8, 9 are of equal length (e.g., within 5 or 10 mm).

[0062] As shown in Figure 20, the assembly comprising the scaffold 230 and lid 270 with the wires 8 and 9 routed and wrapped around the scaffold is inserted into the housing 210 to form the test device 200. Temperature sensors 297, 298 are fitted into the lid 270 prior to insertion into the housing. The tapered rim 278 of the lid forms a tight seal with the housing 210. The fluid in the test device 200 may be heated by a heater similar to heater 112, which may heat the container 2 externally or may be an internal heater immersed in the liquid and / or vapor.

[0063] Thus, an exemplary test apparatus includes a solution and vapor wire corrosion test device 1, 200 with attached wires 8, 9 formed from a conductive material such as copper and having a sufficiently small diameter and sufficient length to allow detection of surface changes at the copper interface as the copper reacts with (or is passivated by) chemical attack, e.g., by additives in the lubricant solution and gas phase. Thin copper wires (e.g., 0.064 millimeter diameter and 1 m length) are generally suitable for such measurements. The scaffolding 30, 230 supports the wire and minimizes tension in the wire. This can improve the accuracy and precision of wire resistance measurements for corrosion testing, as tension differences can result in variations in wire resistance and, as tension, and therefore resistance, can change, resulting in inaccurate corrosion testing of the wire. An exemplary monitoring system 20 (FIG. 1) is configured to accurately measure the resistance and voltage of such relatively small wires at high temperatures. The monitoring system 20 can operate as follows to estimate the rate of corrosion of the wire. The results can be used to assess the suitability of a particular lubricant (or lubricant additive) for use in a machine made of a similar metal that operates with the lubricant, or conversely, the suitability of a machine part for use with a lubricant. According to an exemplary embodiment, copper wire of a fixed length and cross-sectional diameter (e.g., 1 m long and 0.064 mm diameter) is used to obtain a wire size close to that used in automotive gearbox solenoid coils, providing accuracy of the measurement.

[0064] Referring to FIG. 21, an electrical schematic diagram of a test device 1 is shown which may be configured similarly to the test devices described above, except as noted above. The test device may be used in a test fixture as shown in FIG. 1. The test device includes a sealed vessel 2, such as a beaker or other container. The vessel 2 holds a test fluid in liquid (solution) form 4 in a solution space 5, and in vapor (gas) form 6 in a vapor space 7 of the vessel above the solution space 5. The liquid is in contact with the vapor. A first conductive test wire 8 (solution test wire) is at least partially suspended in the liquid 4. A second conductive test wire 9 (vapor test wire) is suspended in the vapor 6, but not in the liquid 4. A first current source 12 is connected across the ends of the first test wire 8 to provide a current through the first test wire. A second current source 18 is connected across the ends of the second test wire 9 to provide a current through the second test wire. A first voltmeter 10 is connected across the end of the first test wire 8 to measure the voltage across the first test wire, and a second voltmeter 16 is connected across the end of the second test wire 9 to measure the voltage across the second test wire. In another embodiment, components 12, 18 are current measuring devices such as ammeters, and components 10, 16 provide a voltage across the wires. In this embodiment, the applied voltage can range from 5 to 800 V. The current range depends on the wire diameter.

[0065] In some embodiments, the first test wire 8 is fully immersed in the solution 4. This may be accomplished by replacing the portion of the wire 8 that extends into the vapor space with a larger gauge or shielded (e.g., coated) wire 400. In the case of the larger gauge wire 400, it may have a diameter (or average cross-sectional area) at least twice, or at least three times, that of the wire 8. As a result, corrosion occurs primarily in the test wire 8. The wire 8 may be soldered or otherwise joined to the wire 400 at the end of the wire 8. In the case of a coating, the vapor phase portion of the wire 8 may be coated with a ceramic or polymer coating, or the like, which limits contact between the fluid and the portion of the wire 8 located in region 7 during testing. In this embodiment, only the unshielded / thinner wire portion is considered in determining the length of the wire 8.

[0066] Wires 8, 9 may be supported on a scaffold (not shown) such as scaffold 30 or 230 described above. Liquid and vapor phase temperature sensors (not shown) similar to sensors 104, 105, 297, 298 may be positioned in vessel 2 to measure the temperatures of liquid 4 and vapor 6, respectively.

[0067] A first electrode 402 is suspended in the vessel 2 so as to be in contact with the liquid 4. A second electrode 404 is suspended in the vessel 2 so as to be in contact with the vapor but not with the liquid. The first and second electrodes 402, 404 are connected to external conductors 406, 408, for example via the lid 64 of the vessel 2.

[0068] Each of the electrodes 402, 404 may function as an anode or a cathode depending on the direction of the current flowing between the electrodes and the wires. The first and second electrodes 402, 404 may be maintained at a constant or alternating potential difference with respect to the wires 8, 9, for example, by one or more current or voltage sources 410, 412, so that current tends to flow between the electrode 402 and the adjacent first wire 8, and between the electrode 404 and the adjacent second wire 9, respectively. Current flowing through the solution (and vapor) between the electrodes / wires can cause electrolysis of one or both of the wires 8, 9, simulating real-world conditions where stray currents can cause loss of mass (or in some cases, gain of mass) of components due to electrolysis. The electrodes 402, 404 may each be formed from a conductive material such as copper, silver, titanium, gold, nickel, platinum, zirconium, niobium, or tantalum, carbon / graphite, alloys thereof, etc.

[0069] A monitoring system 20 is connected to the electrodes 402, 404. As with the apparatus of Figure 1, the monitoring system 20 measures the resistance (or impedance in the case of an AC power source) or other electrical property of the wires as an indication of the change in mass of the wires 8, 9. In this case, the monitoring system 20 may also control the current / voltage applied to the electrodes 402, 404.

[0070] In the embodiment of Figure 21, measurement of the resistance change of the wire allows quantification of the mass change of the wire due to electrolysis and chemical corrosion. This embodiment allows this process to be studied in detail under realistic operating conditions with realistic materials.

[0071] This configuration is also for probing electrochemical reactions that do not occur without applied power.

[0072] Figure 22 shows an exemplary method that may be performed in the test apparatus of Figure 1. The method begins at S100.

[0073] In S102, for example, wires 8, 9 of the same nominal size and composition are provided.

[0074] In S104, the test wires 8, 9 are provided to the scaffold 30, 230 and the ends of the test wires are connected to connectors in the lid 64, 270. This involves wrapping each wire a predetermined number of times around the respective solution space wire support 39, 49, 239, 249 and placing the test wire in the notch. S104 can be repeated for additional sets of wires and scaffolds.

[0075] In S106, the temperature sensors 104 and 105 are fitted into the lid.

[0076] In S108, a measured amount of test fluid, e.g., a liquid such as a lubricant, is inserted into the housing 110. The amount of lubricant or other test fluid is sufficient to immerse the coiled portion of the first test wire 8 in the liquid phase 4 of the test fluid, but space the second test wire 9 away from the liquid phase so that it does not contact it during testing. S108 may be repeated for additional housings and test fluids.

[0077] In S110, the scaffold 30, 230 with attached test wires is inserted into the housing 110 and a lid seals the open (top) end of the housing 110, 210. S108 can be repeated for additional housings and scaffolds.

[0078] At S112, the test wires 8, 9 are connected to respective current sources 12, 18 and voltmeters 10, 16, or alternatively, respective voltage sources and ammeters. The electrodes 402, 404, if used, may be connected to power sources 410, 412 via outer conductors 406, 408.

[0079] At S114, electrical connections are made to the monitoring system 20. In particular, voltmeters 10, 16 (or ammeters) are connected to the monitoring system 20 to record the voltage (or current) across / at the respective test wires 8, 9. Temperature sensors 104, 105 are connected to the monitoring system 20 to record the temperatures of the liquid and vapor phases 4, 6, respectively.

[0080] In S116, the housing 110 may be heated to heat the test fluid and create a vapor phase 6 above the liquid phase 4 of the test fluid. The heater 112 is controlled so that the temperature of the liquid and / or vapor reaches a selected temperature, as measured by a temperature sensor. Once the selected temperature is reached, that temperature is maintained throughout the test. Different housings may be heated to different test temperatures.

[0081] At S118, data is acquired at the monitoring system for each of the set of times (e.g., liquid and vapor phase temperatures and voltages). Data from multiple test wires, e.g., four or eight test wires, may be acquired at the same time. In some embodiments, relay controls 17, 19 may be used to switch between power and measurement states to determine the rate of corrosion of one or both wires.

[0082] At S120, information is calculated by the monitoring system. This may include calculating the resistance of each wire 8, 9 based on the set current and measured voltage at each time period (or vice versa). The resistance may be converted to a corresponding loss in radius (or diameter) of each wire based on the known properties of the wire. For each set of solution and steam test temperatures, a comparable study may be performed. The rate of corrosion (e.g., average loss of wire radius per hour of testing) versus temperature may be determined.

[0083] At S122, the calculated information 22 is output, for example stored in a database, printed, and / or displayed to the user, for example in graphical or tabular format.

[0084] In S124, the tested wires8,9 are examined with an SEM (scanning electron microscope), and the SEM can be used to correlate the wire resistance profile of the fluid, including the solution space and vapor space, to changes on the wire surface. By careful control of these conditions and data logging at sufficiently high speeds, removal of bonded electrons from the metal (e.g., copper) lattice is observed to increase the resistance of the wire as current is passed through it, indicative of removal of metal from the surface, i.e., corrosion.

[0085] The method ends at S126.

[0086] Steps S116 to S122 may be performed automatically by a computer processor implementing software.

[0087] Corrosion Measurement Theory The principle theory behind resistance measurement is Ohm's Law, which states that voltage (V) is equal to resistance (R) multiplied by current (I). Shown as the equation V=I*R, this formula can be rearranged so that if the voltage and current are known, the resulting resistance can be calculated using the equation R=V / I.

[0088] By passing a known constant current or voltage through an electrical conductor, such as a copper wire, and measuring the resulting voltage or current, respectively, one can calculate the resistance. This is the principle on which both standard resistance measurements and platinum measurement thermometers (PRTs) operate. The relationship between temperature and resistance is the basis of how platinum measurement thermometers (PRTs) work.

[0089] In the exemplary setup, constant current sources 12, 18 are used on the test wires 8, 9 to limit the effects of self-heating, which can be a significant enough effect to produce a visible offset in the measurement when current is passed through the wires. Resistance measurements are directly affected by, and therefore related to, changes in temperature of the conductor being measured.

[0090] measurement The exemplary monitoring system 20 may include one or more computing devices having memory that stores instructions for performing data acquisition, data analysis, and data storage, as well as acquired data and processed information 22.

[0091] According to an exemplary embodiment, the data analysis component 26 includes a FLUKE 8846A™ precision digital multimeter (DMM) for measuring the resistance of the copper wire at the start of the test, at the end of the test, and at periodic points throughout the test. The 8846A DMM is a United Kingdom Accreditation Service (UKAS) calibrated measurement device, and is a 6½ digit device with a maximum resolution of 10 μΩ (ten microohms). For each measurement, the DMM and copper wire are allowed to stabilize in a stable temperature controlled room within the range of 19-21° C. before the measurement is taken. This is desirable because resistance is directly related to temperature. Therefore, to obtain an absolute change in resistance, measurements are taken at the same temperature each time. This is described further below.

[0092] Although the FLUKE DMM is very accurate and provides good initial data, it is not suitable or designed to run continuously in a potentially corrosive laboratory environment. Furthermore, the device is limited to a single channel and has no specific logging capability for the data generated. Thus, the data acquisition and logging device 24 may be used to provide accurate measurements on multiple channels based on the resistance measurement theory discussed above.

[0093] The data acquisition component 24 of the monitoring system 20 may include an amplifier module that provides a highly accurate 1 mA / 100 μA excitation current. A suitable amplifier module is the NI-9226 available from National Instruments. The NI-9226 is an 8-channel PT1000 module with a measurement range of 0 to 4,000 ohms.

[0094] The data sampled by the data acquisition device 24 is the raw measured resistance. This resistance can be converted to the resistance at the nominal temperature, if desired, after the sampling has taken place. The exemplary amplifier module is used in the resistance range of solution and vapor phase copper wire and can log up to 8 or 16 channels of data simultaneously.

[0095] For temperature measurements, NI-9216 8-channel PT100 Platinum Measurement Thermometers (PRTs) available from National Instruments may also be used. Such temperature sensors 104, 105 have a measurement range of 0 to 400 ohms. Both the NI-9226 and NI-9216 models have the same temperature measurement range of -200°C to +850°C. To allow for the number of measurement channels desired, two of each module may be installed in a four-slot chassis, thus utilizing all four slots of the chassis. Both modules are operably connected to a suitable data acquisition chassis and then programmed to read, log, and control as desired. Programming of the modules / chassis may be performed using National Instruments' proprietary data acquisition software, LabVIEW™ software. Suitable chassis are available in one, four, and eight slots, and are available in USB, wireless, and Ethernet connection formats, among others.

[0096] According to an exemplary embodiment, a four-slot Ethernet chassis is used to enable up to 16 resistance measurements, or 2×8 channels, to be performed simultaneously utilizing a heating bath 112 large enough to control the temperature of multiple solution and vapor phase wire corrosion test devices 1, 200. Ethernet communications may be used to provide communications from a laptop computer or other computing device to connect to multiple chassis from one central location.

[0097] In one embodiment, the data analysis component 26 converts the measured resistance of the test wire into a diameter of the wire. The change in resistance indicates a change in the diameter (or radius) of the wire, which may be assumed to correspond to the rate of corrosion of the wire.

[0098] The relationship between resistance and wire diameter / radius can be determined by measuring the diameter of wires 8, 9 which exhibit various resistances under test. For example, wire diameter measurements can be made by cutting the wire and examining the cut surface under a microscope.

[0099] Initial testing will be performed in a temperature controlled room using a Fluke DMM. Once testing begins to move to the USB DAQ chassis, accuracy tests will be performed to compare the accuracy of the two acquisition components side by side.

[0100] Depending on accuracy requirements, there can be different monitoring system configurations. The 4-wire configuration is very accurate because it accounts for the measurement lead resistance by using two signal wires that contribute virtually no voltage drop or generation, fed into two very high impedance inputs that effectively draw zero current, and then measure the voltage difference across the wire resistance under test. The voltage generated is therefore the absolute voltage across the resistance.

[0101] It is also common practice to zero the excitation leads and associated connectors, since the leads have their own resistance, and if they are not taken into account, the voltage generated across the leads will be added to the voltage difference across the resistor under test. To zero the leads and connectors, they are connected as closely as possible. The voltage difference measured by the signal input wire is due to the resistance of the lead wires and connectors, which is then stored in the software and used as an offset. This value is negligible, between 1 and 5 mΩ (milliohms), and the larger the test wire, the lower the resistance and therefore the proportionally lower the offset voltage.

[0102] One of the factors that affects the measurements is the environmental temperature offset since the initial start of test (SOT) reading is taken, as well as the time the measurement device and sample are given to stabilize. Since resistance is directly related to temperature regardless of the mechanism used to measure it, a temperature difference between the two measurements will result in a different resistance measurement, and therefore, to measure the absolute change in resistance, it is possible to stabilize all parts of the test equipment in the same conditions as the first measurement, e.g., 12 hours in a temperature controlled room. The other measurements are related to the environment it is exposed to and the conditions when the SOT value is taken.

[0103] Software Systems In one embodiment, the monitoring system uses the following software systems: CATS = Corrosion Analysis Tools and Services: Utilizes a combination of three different programming languages ​​to automate wire corrosion testing and reduce complexity for operators. LIMS (Laboratory Information Management System) (optional) is a laboratory information management system. The CATS client is developed in LABVIEW(TM) CATS Eye was developed at SHINY and is a product of RST.

[0104] This combination of applications is essential for data processing, interpretation, and review of the test results generated. The CATS Client application is responsible for the hardware control and data acquisition. The LIMS is responsible for sample management and uploading of results, as well as providing test specific information for CATS clients. The CATS Eye application is responsible for normalizing and checking the data, generating reports (including plots), and allowing users to explore the data and generate their own comparisons.

[0105] Sample Management CATS LIMS Export Client: The CATS client is configured to retrieve standard CSV files from a LIMS solution, if required, to drive the automatic loading of samples to be tested into the software interface. The LIMS is responsible for managing the test space, sample backlog, test definition, calculations, validation, サード Provides integration with third party software and upload of data. File names are created by the LIMS system that include the batch ID: the instrument in the LIMS without spaces (instrument as in the CATS client instance), the unit name without spaces, the worklist number, and <t>The temperature units in the csv have been corrected.

[0106] The CSV format and summary of the identifiers sent from the LIMS to the CATS client is as follows: The first column of the CSV file is the parent run ID, The second column of the CSV file is the subtest run ID, The third column of the CSV file is the internal material name, e.g., SAMPLEIDENTIFIER1, SAMPLEIDENTIFIER2, SAMPLEIDENTIFIER3, etc.

[0107] The first line of the file is the control standard that is selected as the first run in the LIMS application. PARENTRUNID,SUBTESTRUNID,SAMPLE SAMPLE1, SAMPLE2, SAMPLE3

[0108] Note that when the CATS client reads the file, each sample line provided is doubled in the CATS client interface, except for the first sample, which is the control run. This is to represent the sample being run in solution and vapor. For each run, two result rates are expected from CATS Eye, one for solution and one for vapor.

[0109] LIMS Import from CATS Client After the test is completed, a CSV file is generated when the raw data files are generated from the CATS client.

[0110] In the exemplary surveillance system, the CSV files are used to operatively connect and integrate the CATS Client and CATS Eye.

[0111] In the exemplary monitoring system 20, a SQL (Structured Query Language) database is used by the LIMS. It creates tables for batches and solution and steam wire corrosion test devices to hold the imported data. This is a temporary location to provide connectivity between CATS clients and CATS Eye, rather than moving CSV files across the network.

[0112] According to another exemplary embodiment, data is permanently stored in a row-based structure for cross-sample analysis to enable plotting of historical results. By default, when a batch is created it is marked as unavailable for CATS Eye to extract.

[0113] Complete Data Import In an exemplary monitoring system, the data is imported into a series of tables holding the results of all wire corrosion test devices configured for vapor and solution. Every row of test duration data is imported into the tables and accessible by CATS Eye via the batch ID. According to another exemplary embodiment, the data is processed in memory and not stored in a database.

[0114] Downsampling The LIMS import process also imports rows of data from the raw CSV files at a given sample rate. This is configurable in the LIMS and defaults to every 1000 rows if no value is specified. The structure of the downsampled data provides access to perform cross-sample analysis.

[0115] According to one exemplary embodiment, once a batch is successfully imported into the database, it is marked as available so that CATS Eye can extract the data from the table. According to another exemplary embodiment, the data is immediately processed and available for download.

[0116] CATS EYE IMPORT The internal CATS Eye implementation provides a rate CSV file containing the vapor and solution rate results, which are read from the CSV file into the LIMS and uploaded as measurements.

[0117] Rate Results The solution and vapor wire corrosion test device rate file may contain the following columns: Run ID, Fluid ID (Sample Number), SolFittedCRC, SolTime, SolRate, VapFittedCRC, VapTime, VapRate.

[0118] According to an exemplary embodiment, an internal LIMS solution maps the rate values ​​from the file to the associated run IDs in the units selected for import. These results are then mapped via the LIMS and uploaded to a database for viewing. According to another exemplary embodiment, an external implementation simply provides downloadable PDF and CSV files.

[0119] CATS EYE PDF Results The internal CATS Eye implementation provides a set of PDF files for each subtest run. These documents are located on a network share and are attached to each subtest run as supporting documentation.

[0120] Data Acquisition and Local Storage As mentioned above, the software used to program and run the tests is LabVIEW™, which is a graphically-based software programming language rather than traditional text-based languages. While maintaining a simple yet powerful approach to testing such niche applications, the capabilities and user interface of the software have been significantly revised. A comprehensive list of features supported in the current revision, v3.0, is as follows: 1) Select and connect to either a Link-Local or DHCP online network chassis. 2) Ability to display a test confirmation dialog box if an incorrect network hardware device is selected. 3) Ability to display a test confirmation dialog box if the number of channels specified for resistance does not match the number of temperature channels specified according to the .ini configuration file. 4) Ability to display a test confirmation dialog box if the number of physical hardware channels is not sufficient for the number of channels specified in the LIMS.csv file. 5) Ability to completely stop a test and connect to a different chassis without exiting the application. 6) Ability to stop a test completely and reload the same or an alternate test and continue from the last data logged point. 7) Ability to reload a test and continue from the last data logging point following a failure of the LabVIEW hardware, network connection, or laptop (including a power failure). 8) Dynamically change the number of channels displayed to the number specified by the LIMS.csv file. 9) Dynamically change all button text to show relevant explanations. 10) Dynamically enable / disable buttons to ensure safe and correct operation. 11). Dynamically log the correct number of channels based on the LIMS.csv file, even if more hardware channels than necessary are specified in the ini configuration file. 12) Ability for operator to specify automatic logging rate at any desired interval but with a minimum of 60 seconds / minute. 13) Automatically split each logging file into file sizes specified by the operator in a configuration file. 14) Allows you to create a new exam or reload and resume an old exam. 15) Ability to disable and enable logging during the exam. 16) Ability to pause or completely stop the exam without exiting the application. 17)Ability to pause the exam with option to enable or disable logging and resume. 18) Ability to manually log data to a separate log file on demand. 19) A separate summary file for logging all study-specific data, events, and occurrences that occur during the study. 20) On-screen indicators of specified test data. 21) On-screen indication of the type of test (if any) being performed. 22) On-screen indication of number of logs to test data file. 23) An on-screen countdown for when the next autolog will occur. 24) On-screen indicator of selected logging interval. 25) On-screen indicator of test start date and time. 26) On-screen indicator of total test time elapsed. 27) On-screen indicators of current date, time and temperature. 28) On-screen logging activity indicator. 29) On-screen indication of hardware attributes of connected network devices. 30) On-screen indication of the number of network connection retries allowed. 31) On-screen indicator of currently running network connections. 32) On-screen indication that a network device has connected successfully. 33) On-screen indication of current resistance, start of test resistance, rate of change, and temperature per channel. 34) Open circuit detection with on-screen indicator and logged to summary file per channel. 35) Message-based state machine test sequencing for correct test setup and initiation by operator. 36) Ability to null connectors and leads to eliminate offset errors 37) On-screen countdown allows for stabilization time to be applied per sequence step. 38) Ability to skip the stabilization countdown after it has begun if it is no longer necessary / desired. 39) Ability to cancel test sequencing at any point and return to the start of the test. Ability to define many of the hardware and test specific settings via 40).ini configuration files. 41. Ability to specify hardware channel type, physical slot, physical range, units, calibration data, channel configuration data, and read range in an ini configuration file. 42) Ability to specify whether log data paths are absolute or relative. 43). Ability to specify absolute log data path in ini configuration file. 44). Ability to specify LIMS export paths for CATS in the ini configuration file. 45). Ability to specify path for LIMS import from CATS in ini configuration file. 46). Ability to specify maximum file size per data log file in the ini configuration file. 47. Ability to specify hardware sample rate in the ini configuration file. 48). Ability to specify sample read rate in the ini configuration file. 49).Ability to set open circuit resistance limit value in ini configuration file. Ability to specify display update rate in .ini configuration file. 51). Ability to specify display screen resolution in the ini configuration file. 52). Ability to specify sample read timeout value in ini configuration file. 53).The ability to specify the number of network device connection retries in the ini configuration file. 54). Ability to specify hardware clear task time value in ini configuration file.

[0121] When the application is run, the main screen displays all controls and indicators configured and in the relevant state, so that the only task permitted at this point is to attempt to connect to the desired network chassis. The user presses a button to switch to the relevant connection screen, which allows the user to select from a drop-down menu containing discovered network devices, i.e. devices that are correctly configured and present in the monitoring system and in a state in which they can be connected. Once the desired chassis is selected, the Reserve button is pressed to initiate the connection. The system will attempt to connect to the number of chassis specified in the .ini file settings. The current connection attempt number is displayed on the screen.

[0122] Upon successful connection, device attributes and indicator lights will be displayed on the screen indicating the chassis has been successfully connected. Following a successful connection, the control and indicator states will also change state allowing testing to proceed, including the ability to create a new test or load a previous test to continue from the last logged data point. A currently reserved chassis can only be unreserved if no tests are running.

[0123] If the connection is successful, a logic check is performed to ensure that the number of resistance channels matches the number of temperature channels. If they match, the test continues, if they do not the operator is presented with a confirmation dialog box showing the correct number of each channel. The only option presented is a button to exit the application when the configuration file needs to be modified to ensure the channel numbers match.

[0124] Following a successful connection, a data entry screen is presented to the operator if a new test is selected. As previously mentioned, the LabVIEW system reads the test specific sample information via a standard csv based file generated by the LIMS. This file is selected by the operator in the data entry setup screen. Once the LIMS file is selected, a logical check is performed to ensure that the number of channels requested in the LIMS file can be run based on the total number of hardware channels currently configured in the task. If enough exist, the test continues unhindered, but if there are not enough channels a dialog box is presented which allows the user to either Cancel or End Test. Selecting Cancel allows the user to select a different LIMS file with fewer channels. End Test unreserves the currently connected chassis and closes the application, allowing the user to modify the desired LIMS file or, if possible, reconfigure the hardware settings via a configuration .ini file to allow a greater number of hardware channels in the task.

[0125] Once this file is selected, the data is parsed and relevant information is extracted and updated in other parts of the code. A check is performed to ensure that the test batch name, which is the test log file name, does not contain any illegal characters that Windows cannot process. The operator then proceeds to enter data into all remaining fields which have asterisks. The desired logging rate is also specified here and if a value less than 60 is selected in seconds, the value is converted to 60 as it was agreed that 60 seconds was enough data for the entire test duration for analysis and interpretation. Only when all required fields have been entered and the checks have been completed will the Continue button be enabled. The option to Cancel is available at any time, which will return the user to the main screen.

[0126] When Continue is pressed a check is made to ensure the test file name does not currently exist, if not the test is ignored and continues, if it has been run a confirmation dialog box will appear asking if the operator wants to cancel or overwrite. Cancelling will return you to the data entry screen, overwriting will ask the operator to confirm if they want to do this again as the action cannot be undone.

[0127] Once data entry is complete, the live channel data will be shown with the channel number matching the channel number selected on the data entry screen, the associated button will be enabled or disabled and the test can be started.

[0128] When a load test is selected instead of a new test being selected, a confirmation dialog box asks the user to navigate to a file known as the summary file for that test. The summary file contains all the main event data and test specific information. When a file is selected by the operator, a logical check is performed to ensure that a summary file has actually been selected. Once a valid file has been selected, all relevant data is parsed and the monitoring system is updated with all the relevant information provided by the data entry screens when starting a new test. That is all the operator has to do to reach the same point as if a new test had been created.

[0129] At this point there is an option to cancel the test completely if the user confirms in a confirmation box that they wish to do this. If selected, all test data is cleared and reinitialized, but the connection to the network chassis is maintained. This option to cancel remains until the test has been started, causing the description and functionality to change dynamically.

[0130] If start test is pressed at this point, a message-based state machine will sequentially ask if the user wants to zero the channel, if the user wants to stabilize for a period of time, and ensure everything is connected. Again, the whole process can be canceled at any time. Assuming the test continues, once the final confirmation message is acknowledged, the test will enable all alarms, enable logging, dynamically change button states and descriptions, display log time data and a logging active indicator.

[0131] Auto-log data is logged at a specified rate, while manual log samples can be run any time and any number of times with the click of a button. Test log and time data shows test start date and time, elapsed time, number of logs per file type, and a countdown to the next log. A red LED alternates on and off at a rate of 2Hz with this calculation based on the display update rate set in the configuration .ini file.

[0132] At this point, all live channel data is displayed while the test is running. This includes the current status of the channel as to whether the wire is open circuit or good. The values ​​that determine this are the range of the hardware module as well as the limits set in the configuration .ini file. If the channel resistance exceeds a limit, the monitoring system writes this to a summary file, including the date, time, channel, limit value, and the actual measured resistance. If a channel is suspected to be open circuit, the date and time are displayed on the main screen and the indicator for that channel changes from green to red, clearly indicating that the wire is broken.

[0133] While a test is running, logging can be paused via a button. When pressed, the description and the state of the other buttons change dynamically. The operator can then decide whether to stop the test completely or to re-enable logging.

[0134] If Stop Test is selected, a confirmation dialog box is presented asking if a full unload of the test, pause the test, or cancel is desired. Full unload stops logging, sets all controls and descriptions to their associated states, and closes all log files. Pause simply disables logging and alarms. Pausing and then resuming a test gives the option to continue with or without logging enabled. If they are not enabled, test time data and logging metrics will not be displayed and logging will not be enabled, but alarms will be enabled.

[0135] At any point in the test, or when no test is actually running or connected to a network chassis, if an attempt is made to shut down the main panel or the exit button is pressed, a confirmation asks if they are sure they want to perform that action. If the operator selects "No", the event is ignored and the operator returns to the main screen, but if "Yes" is selected, a sequence of events takes place that stops all logging if enabled, disables alarms if enabled, saves all files and closes them, clears all test data in the monitoring system, and reinitializes all parameters and controls and indicators to their default state. The monitoring system then invokes a stop command which closes the application.

[0136] If an error occurs that is not handled by the error handler, or if the error is fatal, the monitoring system behaves as if the quit or panel close button had been invoked. In this scenario, every attempt is made to save files and close the application as gracefully as possible to reduce file corruption and data loss.

[0137] Sampling and reading rates are set in the .ini configuration file. All logging intervals are based on the calculation of sample rate divided by reading rate. The inverse of this number indicates the sample reading time used to allow for relative and deterministic sampling and logging. This is true for any combination of sample rate and reading rate within the limits of the hardware sampling specification.

[0138] The sampling rate also directly affects the amount of data pushed onto the network, which should ideally be kept low to keep network traffic to a minimum and mitigate potential read issues at the host side due to the amount of sampled data. Each channel is 24 bits. As an example, at a sampling rate of 10Hz, the bit rate is 240 bits per second per channel. There are a maximum of 32 channels (16 resistances and 16 temperatures, both at 24 bits), so a total of 7,680 bits per second. There are 8 bits in a byte, so there are 7,680 / 8=960 bytes of data per second across all channels. 960 bytes=0.960KBps, so not even 1 kilobyte per second. As a reference example, a standard video on YouTube® streams at about 94KBps.

[0139] As another example, assuming the same 32x24 bit channels as above, but with a sampling rate of 2kHz, the bit rate would be 48,000 bits / second per channel, for a total of 1,536,000 bits / second, or 1.536Mbps. This equates to 192,000 bytes, or 192KBps of data per second across all channels.

[0140] Alternative measurement methods The above technique based on the PRT methodology is a simple yet very effective means of measuring resistance and is easily expandable to also obtain temperature via the same module, however it does have limitations. As mentioned previously, PRT type systems are limited to measuring within the operating range of 0Ω to 400Ω, which is the operating range of the PT100, however the same principle of exciting a resistive element and measuring the voltage difference produced is exactly how a thermistor works.

[0141] The main difference between thermistors and PRTs is their operating range and their sensitivity to temperature changes. Usually thermistors have a much smaller operating temperature range but are very sensitive to very small changes in temperature. PRTs have a much lower sensitivity level but a much larger operating temperature range. A PRT module is an all-in-one compensation module, whereas a separate current output module and analog input voltage module are required to excite and read the sensor separately. Then the accuracy of both modules needs to be calculated at both extremes to understand the true accuracy of the settings. The PRT module in this application will always be more accurate because it has a dedicated range to measure the set constant current output and everything contained in a single compensation module.

[0142] Another way to detect changes in resistance is through the use of a Wheatstone bridge. There are variations of the Wheatstone bridge that can be used to measure load, force, temperature and resistance etc, but all are built on the basic principle of four resistors using two pairs of resistors placed in parallel with each other. Three of the resistors are static values. The fourth resistance is a variable that changes with changes in temperature or actual resistance.

[0143] As with the PRT and thermistor setup, the bridge is excited with either a voltage or current (AC or DC) and the corresponding differential signal is read. If all resistances are equal at the start of the test, the bridge is considered balanced and read as zero input. If the fourth resistor changes, whether due to temperature or due to an actual change in resistance, the bridge becomes proportionately unbalanced and the differential signal is measured proportional to the voltage exciting it.

[0144] The disadvantage of the Wheatstone bridge in this case is that, although very accurate, all resistors in the bridge must be exposed to the same environmental temperature to perform temperature compensation. Any temperature change in one resistor will cause the bridge to experience an error in the differential output signal. The other temperature-related issue in this case is the self-heating effect, which is high and shows up as a temperature offset, but is interpreted as a change in actual resistance. The only way to prevent this is to use a much higher resistance, but with a specific Wheatstone bridge amplifier for precise control of the excitation voltage and signal measurement. UDIO and R (R Development Core Team).

[0145] Data Analysis and Reporting symbol constant r0 = initial wire radius (set to 3.2 × 10-5 m, for example). ρ 標準 = resistivity of the wire metal at standard temperature (for copper, 1.68 x 10-8 Ωm at 20°C). T 標準 = standard temperature used for resistivity (set for example to 20°C). α = temperature coefficient of resistivity (3.86 x 10 for copper) -3 K -1 ) l 標準 = standard length of wire (set to 1.01m for example). ε t = the tolerance allowed in oil temperature (set for example at 5°C). T 標的 = target oil temperature (e.g., one of 80, 100, 120, 130, 140, 150, 170, and 180°C). variable R = measured resistance, ohms. t = elapsed time, seconds. T = measured oil temperature, °C

[0146] The input data may include the following input values ​​(e.g., column-wise or as comma separated values ​​(CSV): date and time, measured temperature per wire corrosion test device in solution phase, measured temperature per wire corrosion test device in gas phase, measured resistance per wire corrosion test device in solution phase, measured resistance per wire corrosion test device in gas phase.

[0147] The following steps may be performed separately for each wire corrosion test device, in both solution and gas phase. 1) Delete the first hour of data because the temperature is unstable at this point. Set t=0 at the start of the trimmed data. 2) Calculate the resistivity at the measured temperature. ρ = ρ 標準 +((TT 標準 )×α×ρ 標準 3) Estimate the length of the wire, l.

number

number

number

[0148] If a large number of data are collected, the data can be downsampled before being plotted. For example, if data is collected every 10 seconds for 10 days, 86,400 rows of data are obtained per oil. These can be downsampled by a factor of 100 or even 1000 without losing much information.

[0149] The data can be plotted on a graph of corrosion (radius loss) versus time so that several lubricants can be compared, or the same oil at multiple temperatures can be compared. The Loess Smoother can be fitted to the data for each oil at each temperature separately. If an oil has more than 200 data points, a subset of 200 can be used to fit the Loess to improve calculation speed. The smoother fit value at t=0 is replaced by 0.

[0150] The overall corrosion rate can be calculated as the final fitted corrosion either at the end of the test or just before wire breakage and divided by the time it was observed. Overall rates for the same fluid at a range of temperatures can be measured and compared on an Arrhenius plot, which plots 1 / ln(rate) versus 1 / temperature on the Kelvin scale.

[0151] Figure 23 shows data collection and processing in one embodiment. At S300, the following steps are performed on the CATS client: At S302, the method is started. At S304, CATS is opened. At 306, the sample name is entered and stored, for example by a user. At 308, the unit is placed in the rack. At S310, the unit is connected. At S312, the test is started. At S314, the test is run. At S400, to store the data, a shared raw data file is created (S402).

[0152] At S500, the following steps are performed at the CATS eye client: At S502, the CATS eye cloud solution may be accessed; At S504, user authentication is optionally performed; At S506, a raw data file is selected; At S508, data is imported from the raw data file; At S510, data may be downsampled and calculations performed; At S512, a report 22 is generated and output, and at S514, the data processing method ends.

[0153] The disclosed testing devices, scaffolds, and testing apparatus can provide one or more of the following advantages: 1) It reduces the time it takes to install the wire being tested. 2) Facilitates temperature measurements in both the solution and gas phases for use in subsequent calculations and corrections. 3) Time and resource savings through automated data processing and reporting of wire corrosion results for both solution and vapor phase wire tests, including automatic quantitative calculation of corrosion products from measured electrical resistance of wires of known initial thickness and length, normalization of measured data to account for temperature dependence and thermal expansion and length variations, and significantly reduced test reporting times. 4) Simultaneous measurement of solution and gas phase corrosion in real time with fully integrated sample management and automated data processing and interpretation. 5) Automatic presentation of generated data in multiple formats such as corrosion versus time, and if temperature data is present, simple dynamic plots such as Arrhenius plots can be generated. 6) Ease of connecting the test wires to external wires via a quick connection in the lid of the device. 7) A scaffold that supports both solution and vapor phase wires. 8) A device wire lid that provides electrical connections to test wires and temperature measuring devices to perform wire resistance and temperature measurements. 9) Reduced mass versus single wire zigzag peg designs. 10) Lower and upper wire support sections that are different diameters to provide controlled routing wire lengths for the solution phase wire and the vapor phase wire, respectively. 11) Wire alignment notches in the scaffold to provide defined spacing of solution and vapor phase wires. 12) Wire connections for solution and vapor wires on lids of devices of different sizes and / or shapes, thus reducing operator error. 13) A scaffold having a flat base to provide stability to the scaffold during assembly and within the housing. 14) Lids that all have tapered surfaces to seal against the container (the taper accommodates dimensional variations in the glassware) and reduced gaps between the lid and the top of the container that can cause airflow into the container and thereby poor temperature control of the solution and gas phases. 15) Solution and vapor space temperature measurements using two RTDs in the test vessel to allow for temperature compensation. One RTD is utilized in the solution phase space and the other in the vapor phase space.

[0154] Example 1 Tests are carried out to simulate corrosion in the coils of an automotive gearbox solenoid. Such solenoids often have a wire diameter of about 0.128 mm. The test wires 8, 9 used in the tests are selected to have a diameter as close as possible to the real solenoid wires, but also to have a resistance that can be accurately measured by the scope of the monitoring system 20. The value chosen for the tests is a copper wire with a diameter of 0.064 mm at a nominal length of 1 m. This gives the following resistances for the given diameters: [Table 1]

[0155] Testing is performed using a test device 1 (as shown in Figures 1 and 12-20) and corresponding scaffold 230, and multiple copies of the software described above.

[0156] A standard Ethernet-based data acquisition chassis is used in one implementation of the test equipment as disclosed herein. Table 1 contains a list of the National Instruments hardware used. [Table 2]

[0157] Alternatively, an 8-slot USB chassis and one 9217PRT module are used for the monitoring system. These allow direct and instant connection to the chassis within minutes without worrying about communication loss. This chassis is also suitable for running the maximum number of channels that will fit into one suitable heating bath. A direct connection between each chassis and a laptop / PC is used. This arrangement may not be practical for commercial applications because the USB cables run long distances and the number of chassis is limited to the number of USB ports on the laptop / PC. An Ethernet-based chassis can easily overcome these issues.

[0158] The data is collected in a data file, for example as comma separated values, an example of which is shown in Table 2 below. [Table 3]

[0159] Figure 24 shows an example of a graph of radius change (nm) versus time for a wire undergoing a wire corrosion test in solution phase over time at multiple temperatures. Figure 25 shows an example of a graph of radius change (nm) versus time for a wire undergoing a wire corrosion test in gas phase over time at multiple temperatures.

[0160] Figure 26 shows an Arrhenius plot of the corrosion characteristics of a solution-phase wire, i.e., corrosion rate as a function of temperature, and Figure 27 shows an Arrhenius plot of the corrosion characteristics of a vapor-phase wire, i.e., corrosion rate as a function of time, that may be generated from the graphs of Figures 24 and 25. If desired, the plots can be fitted to straight lines.

[0161] The output report 22 of the wire corrosion test may include one or more of the graphs in Figures 24-27 and / or a tabular representation of the corrosion characteristics of the solution phase wire and the vapor phase wire over time for multiple temperatures. An exemplary table is shown in Table 3. [Table 4]

[0162] FIG. 28 shows an example of an exemplary output report 22 of a wire corrosion test including LabView input data 500, temperature and wire radius data 502, and one or more plots 504, 506 of the solution / vapor wire over time at multiple temperatures, such as a plot (or multiple plots) 504 of radius change, as shown in FIGS. 24 and 25, and an Arrhenius plot (or multiple plots) 506 showing the corrosion rate as a function of temperature for the solution / vapor wire, as shown in FIGS. 26 and 27.

[0163] In a separate test, plots of corrosion (change in radius) versus time for solution-phase and vapor-phase wire corrosion tests against an aggressive oil for copper are generated and compared with similarly obtained plots when four different additive packages are added in different ratios. The results obtained are shown in Table 4. [Table 5]

[0164] The use of the corrosion inhibitor appears to have minimized the amount of copper corrosion (very little increase in resistance over time), which correlates with post-test SEM-EDX (scanning electron microscope-energy dispersive X-ray) analysis of the copper wires, which shows an increase in copper diameter due to the inhibitor layer used.

[0165] When compared to the ASTM D130 corrosion strip surface analysis test method, previously invisible differences between fluids are easily observed, and differences in both total resistance and rate of resistance increase are examples of such phenomena that can now be used to quantify copper corrosion of different fluids. In fact, only good and poor performing chemical formulations can be distinguished from one another when rated using the ASTM D130 method. However, using the methods and systems disclosed herein, distinctions between different lubricant formulations can be observed and quantified, providing information about corrosion that was previously only distinguishable with copper strip surface analysis.

[0166] Some of the detailed descriptions herein are presented in terms of algorithms and symbolic representations of operations on data bits performed by conventional computer components, including a central processing unit (CPU), memory storage devices for the CPU, and associated display devices. These algorithmic descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is generally conceived as a self-consistent sequence of steps leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It is sometimes convenient, primarily for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.

[0167] It should be understood, however, that all of these and similar terms are associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless otherwise indicated, and as will be apparent from the discussion herein, throughout the description, discussions utilizing terms such as "processing" or "computing" or "calculating" or "determining" or "displaying" refer to the actions and processes of a computer system or similar electronic computing device that manipulates and converts data represented as physical (electronic) quantities in the computer system's registers and memory into other data similarly represented as physical quantities in the computer system's memory or registers or other such information storage, transmission or display device.

[0168] Exemplary embodiments also relate to an apparatus for performing the operations discussed herein. This apparatus may be specially constructed for the required purposes or may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such computer programs may be stored in a computer-readable storage medium, such as, but not limited to, any type of disk, including floppy disks, optical disks, CD-ROMs, and magneto-optical disks, read-only memory (ROM), random access memory (RAM), EPROM, EEPROM, magnetic or optical cards, or any type of medium suitable for electronic instruction imprinting, each connected to a computer system bus.

[0169] The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Various general-purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct more specialized apparatus for performing the methods described herein. The structure of a variety of these systems will be apparent from the above description. Moreover, the exemplary embodiments are not described with reference to any particular programming language. It will be understood that a variety of programming languages ​​may be used to implement the teachings of the exemplary embodiments as described herein.

[0170] A machine-readable medium includes any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer). For example, machine-readable media include read-only memory ("ROM"), random-access memory ("RAM"), magnetic disk storage media, optical storage media, flash memory devices, and electrical, optical, acoustic, or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.), to name a few.

[0171] The methods described throughout the specification may be implemented in a computer program product that can be executed on a computer. The computer program product may comprise a non-transitory computer-readable recording medium on which a control program is recorded, such as a disk, a hard drive, etc. Typical forms of non-transitory computer-readable media include, for example, a floppy disk, a flexible disk, a hard disk, a magnetic tape, or any other magnetic storage medium, a CD-ROM, a DVD, or any other optical medium, a RAM, a PROM, an EPROM, a FLASH-EPROM, or any other memory chip or cartridge, or any other tangible medium that can be read and used by a computer.

[0172] Alternatively, the method may be implemented in a transitory medium such as a transmittable carrier wave in which the control program is embodied as a data signal using a transmission medium such as acoustic or light waves, such as those generated during radio wave and infrared data communications.

[0173] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be made thereafter by those skilled in the art that are also intended to be within the scope of the following claims.< / t>

Claims

1. A scaffolding, a plurality of spaced apart lower support members, each of the plurality of spaced apart lower support members including a plurality of first routing supports for spacing a plurality of turns of an associated first test wire for immersion in a liquid phase of a test fluid when the associated first test wire is wound around the plurality of spaced apart lower support members at the plurality of first routing supports; a plurality of spaced apart upper support members, each of the plurality of spaced apart upper support members including a plurality of second routing supports for spacing a plurality of turns of the second test wire for positioning the test fluid above the liquid phase when the test fluid is in a gas phase when the associated second test wire is wound around the plurality of spaced apart upper support members at the plurality of second routing supports; a closure member providing a connection between an end of the first test wire and a respective associated first outer conductor and providing a connection between an end of the second test wire and a respective associated second outer conductor, the closure member or a first upper cross member attached thereto being attached to a first end of each of the plurality of upper support members; a second cross member spaced longitudinally from the closure member, the second cross member attached to a first end of each of the plurality of lower support members and attached to a second end of each of the plurality of upper support members to laterally space the plurality of lower support members and the plurality of upper support members; Provided with scaffolding.

2. 2. The scaffolding of claim 1, further comprising a third cross member longitudinally spaced from the closure member by the second cross member, the third cross member being attached to a second end of each of the plurality of lower support members.

3. The scaffolding of claim 1 , wherein at least one of the first routing supports on the lower support member includes an opening for receiving the first test wire therethrough.

4. The scaffolding of claim 1 , wherein the first plurality of routing supports and the second plurality of routing supports are longitudinally spaced apart on their respective upper and lower support members.

5. 2. The scaffolding of claim 1, wherein each of the lower support members includes at least three of the first routing supports and each of the upper support members includes at least three of the second routing supports.

6. 2. The scaffolding of claim 1, wherein the upper and lower support members are cylindrical and extend longitudinally parallel to one another.

7. 2. The scaffolding of claim 1, wherein there are at least four upper support members and / or at least four lower support members.

8. The scaffolding of claim 1 , wherein the upper support member is offset from the lower support member in an arc.

9. 2. The scaffolding of claim 1, wherein the second cross member includes arcuately spaced slots, the second ends of the upper support members being received in every other one of the arcuately spaced slots, and the first ends of the lower support members being received in every remaining one of the arcuately spaced slots.

10. The scaffolding of claim 1 , wherein the closure member includes holes for receiving first and second temperature sensors.

11. The scaffolding of claim 1 , wherein equal routing lengths are provided for the first and second test wires.

12. 2. The scaffolding of claim 1 , wherein the plurality of spaced apart lower support members are longitudinally aligned with a central axis of the scaffolding and the plurality of spaced apart upper support members are longitudinally aligned with the central axis of the scaffolding.

13. A combination of the scaffolding described in claim 1 and the first and second test wires included therewith, wherein the first and second test wires are conductive, and the combination constitutes an assembly.

14. A combination of the scaffold of claim 1 and a housing included therewith, wherein the housing is shaped to receive the scaffold, and the closure member of the scaffold closes an upper end of the housing to form a container for holding and containing an associated test fluid, the liquid phase of the test fluid contacting the first test wire and any gas phase of the test fluid present contacting the second test wire, and the combination constituting a testing device.

15. The test fluid comprising: a liquid phase temperature sensor positioned within the housing to measure a temperature of the liquid phase of the test fluid; and a vapor phase temperature sensor positioned within the housing to measure a temperature of the vapor phase of the test fluid; a heater configured to heat the liquid phase of the test fluid within the housing to form the gas phase of the test fluid; 15. The combination of claim 14 further comprising:

16. and one of a first electrical system and a second electrical system, the first electrical system comprising: a first current source connected across an end of the first test wire to provide a first current through the first test wire; a second current source connected across an end of the second test wire to provide a second current through the second test wire; a first voltmeter connected across an end of the first test wire to measure a first voltage across the first test wire; a second voltmeter connected across an end of the second test wire to measure a second voltage across the second test wire; Equipped with the second electrical system: a first voltage source connected across an end of the first test wire to generate a first voltage across the first test wire; a second voltage source connected across an end of the second test wire to generate a second voltage across the second test wire; a first ammeter connected across an end of the first test wire to measure a first current across the first test wire; a second ammeter connected across an end of the second test wire to measure a second current across the second test wire; 15. The combination of claim 14 comprising:

17. first and second electrodes, the first electrode immersed in the liquid phase of the test fluid and the second electrode positioned above the gas phase of the test fluid where the test fluid may be present; a first voltage or current source connected to the first electrode and for passing a first current between the first electrode and the first wire; a second voltage or current source connected to the second electrode and for passing a second current between the second electrode and the second wire; 15. The combination of claim 14 further comprising:

18. A combination of the testing device described in claim 16 and a monitoring system included therewith, wherein the monitoring system receives signals from the first voltmeter and the second voltmeter or from the first ammeter and the second ammeter and calculates and outputs information based thereon, the combination constituting a testing apparatus.

19. The monitoring system comprises: a data acquisition component that acquires at least one of a first acquired voltage, a second acquired voltage, a first acquired current, and a second acquired current over each of the first and second test wires over time; a data analysis component that processes the at least one of the acquired first voltage, the acquired second voltage, the acquired first current, and the acquired second current a plurality of times and calculates the information based thereon; an output component for outputting the information; 20. The combination of claim 18 further comprising:

20. 20. The combination of claim 19, wherein the information includes a measurement of corrosion of each of the first and second test wires.

21. 21. The testing apparatus of claim 20, wherein the measurement of corrosion of each of the first and second test wires comprises a calculated change in diameter or radius of each of the first and second test wires.

22. 20. The testing apparatus of claim 19, wherein the information comprises a measurement of corrosion as a function of temperature of the liquid phase of the test fluid.

23. The method of claim 22, comprising the steps of: wrapping a first test wire around a plurality of spaced lower support members of the scaffold for immersion in a liquid phase of a test fluid; wrapping a second test wire around a plurality of spaced apart upper support members of the scaffold for positioning above the liquid phase of the test fluid where the test fluid is in a gas phase; providing a housing having an open end for receiving and containing a test fluid, said scaffolding and said first and second test wires wrapped around said plurality of spaced apart lower and upper support members; providing a closure member for closing said open end of said housing; introducing the test fluid into the housing; inserting the scaffold and the first and second test wires wrapped around the plurality of spaced apart upper and lower support members into the housing, thereby the first test wire wrapped around the plurality of spaced apart lower support members is immersed in the liquid phase of the test fluid; the second test wire wrapped around the plurality of spaced apart upper support members is positioned above the liquid phase of the test fluid while the test fluid is in the gas phase; The closure member closes the open end of the housing. And, heating the liquid phase of the test fluid in the housing to generate a gas phase of the test fluid that, when generated, contacts the second test wire wrapped around the plurality of spaced apart upper support members of the scaffold; Measuring at least one electrical characteristic of each of the first and second test wires that may vary over time; and determining information based on any changes in the electrical characteristic of each of the first and second test wires; A method comprising:

24. 24. The method of claim 23, wherein the measurement of the at least one electrical characteristic over time of each of the first and second test wires includes one of a current and a voltage, or one of the current and voltage being controlled.

25. 24. The method of claim 23, wherein the test fluid comprises at least one of a coolant and a corrosion inhibitor.

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