Corrosion Sensor Manufacturing via Discrete Electrode Deposition
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Solution Overview
Problem
Conventional corrosion sensors are prone to crevice corrosion, which degrades their sensitivity and accuracy over time due to the degradation of the bond between electrodes and dielectric material, leading to inaccurate monitoring of corrosion rates in harsh environments.
Innovation Solution
The method involves manufacturing corrosion sensors using direct write deposition techniques to create smaller, closely spaced conductive portions with a seamless interface to the non-conductive portions, reducing crevice corrosion by using materials like platinum, palladium, or gold, and applying a non-conductive material around discrete conductive locations to prevent gaps and ensure a metallurgical bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional corrosion sensors use alternating layers of electrodes and dielectric material, then the sensor can monitor general corrosion rates, but the bond between electrodes and dielectric material degrades over time creating gaps that lead to crevice corrosion
Solution Approach 1:
The patent changes the geometric parameters of the electrode structure from continuous alternating layers to discrete islands or patches. This parameter change eliminates the bond interface between electrodes and dielectric material, preventing crevice corrosion while maintaining the ability to monitor corrosion rates through the exposed electrode surfaces.
Solution Approach 2:
The continuous electrode layers are segmented into discrete islands or patches distributed across the substrate. This segmentation eliminates the problematic bond interfaces between electrodes and dielectric material that occur in conventional layered structures, thereby preventing crevice corrosion and improving sensor reliability over time.
2Measurement precision
If the bond between electrodes and dielectric material is strong initially, then the sensor provides accurate measurements, but the bond degrades over time creating low flow regions conducive to crevice corrosion
Solution Approach 1:
The patent extracts and eliminates the dielectric material layer that bonds to electrodes in conventional sensors. By removing this component entirely and using discrete electrode islands on a substrate, the design eliminates the bond interface that degrades over time and creates crevice corrosion, while maintaining measurement precision through direct electrode exposure to the environment.
3Area of stationary object
If crevice corrosion occurs between electrodes and dielectric material, then larger surface area of electrodes is exposed to hot gas path, but this increases electrical potential and current flow changing sensor calibration
Solution Approach 1:
The patent applies a protective coating to the substrate before depositing the discrete electrode islands. This preliminary action prevents crevice corrosion from occurring at the substrate-electrode interfaces, ensuring that electrode surface area increases do not lead to uncontrolled changes in electrical potential and current flow, thereby maintaining sensor calibration accuracy.
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
This approach enhances the sensors' resistance to crevice corrosion, maintaining accuracy and reliability by preventing crevice corrosion and allowing for the detection of smaller corrosion rates, making them suitable for harsh environments.
Implementation Method 1
spraying a conductive material at discrete locations on the substrate or on the non-conductive material
Implementation Method 2
spraying the non-conductive material around the discrete locations of the conductive material
Implementation Method 3
The general corrosion is characterized by an oxidation-reduction reaction in which the metal surfaces are oxidized, producing an anode at the oxidation site and a cathode at the reduction site
Data Source
AI summary
A method for manufacturing a corrosion sensor includes spraying a non-conductive material on a substrate and spraying a conductive material at discrete locations on the substrate or on the non-conductive material. The method further includes spraying the non-conductive material around the discrete locations of the conductive material.