2017 Award Nomination Title of Innovation: Nondestructively Measure TSA on Stainless Steel

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Miranda Parsons
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1 2017 Award Nomination Title of Innovation: Nondestructively Measure TSA on Stainless Steel Nominee(s) Fischer Technology, Inc. Category: (select one below) Coatings and Linings Cathodic Protection Materials Design Chemical Treatment Instrumentation Testing Integrity Assessment Other fill in Dates of Innovation Development: Brought to market in 2016 Web site: Summary Description: New advancements in Fischer s phase-sensitive eddy current technology have produced a new probe, ESD20-TSA. It was designed specifically for nondestructive measurement of thermal spray aluminum (TSA) directly over nonferrous metals i.e. stainless steel and aluminum. Thermal spray aluminum (TSA) is a thick coating over metal used to prevent stress corrosion on offshore constructions and other parts exposed to corrosive salt water and harsh environmental conditions. Correct thickness of the TSA coating is critical for its long term corrosion preventive qualities. Previously traditional methods of measuring TSA over stainless steel were costly 1

2 and cumbersome. Phase-sensitive eddy current is a unique test method using differences in electrical conductivity of distinct material layers to accurately measure metals applied to metals. The following applications can be done easily and accurately with the PHASCOPE PMP10 and the new ESD20-TSA probe: TSA / Aluminum TSA / Stainless steel TSA / duplex steels TSA / carbon steel TS-Zn / carbon steel Paint / TSA / Stainless steels Phase-sensitive eddy current makes it possible to measure TSA coatings on both carbon AND non-magnetic stainless steel with a single device. The advantages of phase-sensitive eddy current probes are excellent repeatability. They are able to measure rough coatings, rough substrates, curved parts and measure lift off. Readings can be taken individually or according to SSPC-PA2 specifications. The ESD20-TSA probe is available from any Fischer Group location around the world. 2

3 Full Description: (Please provide complete answers to the questions below. Graphs, charts, and photos can be inserted to support the answers.) 1. What is the innovation? Fischer has developed a new probe for nondestructively measuring the thickness of thermal spray aluminum (TSA) coatings on nonferrous metals. The new ESD20-TSA probe used with the handheld gauge, PHASCOPE PMP10 easily measures thick TSA coatings. 2. How does the innovation work? Phase-sensitive eddy current is a unique test method using differences in electrical conductivity of distinct material layers to accurately measure metals applied to metals. Phase-sensitive eddy current makes it possible to measure TSA coatings on both carbon AND non-magnetic stainless steel with a single device. 3. Describe the corrosion problem or technological gap that sparked the development of the innovation? How does the innovation improve upon existing methods/technologies to address this corrosion problem or provide a new solution to bridge the technology gap? Thermal spray aluminum (TSA) is a thick coating of metal and used to prevent stress corrosion on offshore constructions and other parts exposed to corrosive salt water and harsh environmental conditions. Correct thickness of the TSA coating is critical for its long term corrosion preventive qualities. Until now, the industry did not have an effective way to nondestructively measure TSA coatings applied to nonferrous substrates, i.e. stainless steel, aluminum, duplex coatings. Previously, testing was done on carbon steel coupon samples that were coated alongside the actual structure and the thickness was inferred from the coupon. Actual field measurement, of the TSA thickness, as applied to the true structure, was not possible without a destructive test. The Fischer PHASCOPE PMP10 w/ ESD20TSA solves this problem as it can measure the following applications in the field: TSA / Aluminum TSA / Stainless steel TSA / duplex steels TSA / carbon steel TS-Zn / carbon steel 3

4 Paint / TSA / Stainless steels The advantages of phase-sensitive eddy current probes are they are able to measure rough coatings, rough substrates, curved parts and measure lift off along with excellent repeatability. Readings can be taken individually or according to SSPC-PA2 specifications. 4. Has the innovation been tested in the laboratory or in the field? If so, please describe any tests or field demonstrations and the results that support the capability and feasibility of the innovation. Testing has been completed in both laboratories and in the field. Validation of measurement performance has been confirmed with standard measurement tools (e.g. calipers, micrometers) or with TSA applied to carbon steel coupons and measured with Fischer s NIST traceable magnetic induction methods. Method validation: Strategy 1: Prepare partially coated samples > Comparison of PS-EC measurements with mechanical tester results Strategy 2: coat SS and CS in parallel (same thickness) > measure TSA/CS with MI and use values as ref for PS-EC on TSA/SS Strategy 3: cross-section analysis of coating thickness The repeatability performance of the PS-EC method is excellent Calibration measurements with mechanical / MI / cross-section measurements are often subject to heavy scattering (roughness). Good averaging of these methods necessary. Total uncertainty is 5-10% 5. How can the innovation be incorporated into existing corrosion prevention and control activities and how does it benefit the industry/industries it serves (i.e., does it provide a cost and/or time savings; improve an inspection, testing, or data collection process; help to extend the service life of assets or corrosion-control systems, etc.)? Measuring the TSA coating thickness ensures that the correct amount of material is being used for corrosion protection and to prevent the inefficiency and waste of under or over applying. With the ESD20TSA 4

5 probe and PHASCOPE PMP10 readings can be taken individually or according to SSPC-PA2 specifications. Previously, testing was done on carbon steel coupon samples that were coated alongside the actual structure and the thickness was inferred from the coupon. Extra coating material was needed for the coupon and it needed to be coated at the same rate as the actual structure. 6. Is the innovation commercially available? If yes, how long has it been utilized? If not, what is the next step in making the innovation commercially available? What are the challenges, if any, that may affect further development or use of this innovation and how could they be overcome? Yes, the ESD20TSA probe was developed in 2015 and is available from any Fischer Group location around the world. 7. Are there any patents related to this work? If yes, please provide the patent title, number, and inventor. N/A 5

Dates of Innovation Development: January, 2014 to July 2015 Web site: Summary Description: Cathodic Protection

Dates of Innovation Development: January, 2014 to July 2015 Web site: Summary Description: Cathodic Protection 2017 Award Nomination Title of Innovation: Ultrasound Cathodic Protection Test Station Nominee(s) Eugene (Gene) B. Silverman PhD, Berkeley Springs Instruments LLC Category: Cathodic Protection Coatings