Corrosion Proxy Thin Film Sensor for Early Onset Detection
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Solution Overview
Problem
Existing corrosion monitoring technologies are inadequate for subsurface and harsh environments due to limitations in withstanding high temperatures and pressures, and lack of suitable optical sensor elements for chemical species detection, necessitating the development of alternative methods for early corrosion onset detection and quantification in critical infrastructure.
Innovation Solution
Integration of 'corrosion proxy' materials with advanced sensor device platforms like optical fiber and surface acoustic-wave devices, which allow for wireless and distributed monitoring of corrosion through changes in mass, optical, electrical, or strain properties, enabling proactive measures against degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical and electronic sensor components are used in subsurface environments, then sensing capability is provided, but reliability deteriorates due to inability to withstand high temperatures and pressures
Solution Approach 1:
The patent replaces electrical and electronic sensor components with optical-based sensing systems. Optical fibers and optical sensors are used instead of conventional electrical sensors, eliminating the reliability issues associated with electrical components in high-temperature and high-pressure subsurface environments. The optical system uses light propagation and optical property changes to detect corrosion without requiring electrical connections or electronic components at the sensing location.
2Reliability
If optical sensor elements are used for chemical species detection, then safety is improved by eliminating electrical components, but measurement precision deteriorates due to lack of suitable optical sensor elements
Solution Approach 1:
The patent introduces corrosion proxy materials as intermediaries between the corrosive environment and the optical sensor. These proxy materials are specifically selected or engineered to undergo corrosion reactions that produce measurable changes in optical properties (refractive index, absorption, scattering). The proxy material acts as a mediator that translates chemical corrosion processes into optical signals that can be detected with high precision by the optical sensor system.
Solution Approach 2:
The patent utilizes changes in optical parameters (refractive index, absorption coefficient, scattering properties) of corrosion proxy materials as corrosion progresses. By monitoring these optical parameter changes, the system achieves precise measurement of corrosion onset and progression while maintaining the safety advantages of electrical-component-free sensing.
3Area of stationary object
If distributed sensing is implemented for wide-area monitoring, then coverage area is improved, but device complexity increases
Solution Approach 1:
The patent employs a universal optical fiber-based sensing platform that can perform multiple functions: temperature sensing, pressure sensing, and corrosion detection through the corrosion proxy materials. This multi-functional approach allows distributed sensing over wide areas using a single type of sensor system, reducing the complexity that would arise from deploying multiple specialized sensor types across the infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables early detection and quantification of corrosion in critical infrastructure, providing a cost-effective and safe solution for wide-area monitoring in harsh environments, reducing the risk of costly and hazardous failures.
Implementation Method 1
a corrosion proxy thin film that corrodes at a rate where the normalized change of mass of the film over time is greater than the normalized change of mass of the bulk material of the host component
Implementation Method 2
Changes in optical, electrical, strain/stress, or even mass properties of the 'corrosion proxy' sensing materials as a result of characteristic corrosion reactions can be monitored through these advanced sensor device platforms
Implementation Method 3
Passive, microwave sensor technologies such as surface acoustic wave devices also offer similar, unique advantages in that they allow for remote and wireless interrogation without the need for electrical wires or contacts at the sensing location
Data Source
AI summary
Embodiments relate to methods, systems and apparatus for detecting corrosion using a detector apparatus with a host component. The method includes a detector apparatus. The detector apparatus includes an energy source; a corrosion proxy thin film that corrodes at a rate where the normalized change of mass of the film over time is greater than the normalized change of mass of the bulk material of the host component in a harsh environment; and the detector, wherein the detector is capable of detecting a change in energy due to corrosion of the corrosion proxy thin film. The method includes exposing the host component and the corrosion proxy thin film to the harsh environment; and detecting a change in energy using the detector due to corrosion of the corrosion proxy thin film.