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Sensor-based method enables real-time monitoring of corrosion onset in coatings
A novel sensor-based technique allows non-destructive, real-time investigation of transport processes in organic coatings. The Belgian research team validated the approach using advanced electrochemical impedance methods.
A research team has developed an innovative methodology for assessing transport properties and corrosion onset in organic protective coatings. This sensor-based approach enables non-destructive, in-situ monitoring of capacitance changes triggered by electrolyte diffusion through the coating. Compared to traditional techniques, the method provides immediate insight into water uptake and diffusion behaviour, offering new potential for understanding corrosion protection mechanisms.
To validate their approach, the researchers combined sensor measurements with Odd Random Phase Electrochemical Impedance Spectroscopy (ORP‑EIS). This technique provides rapid assessment of early water uptake and allows determination of diffusion coefficients. Strong correlation between the sensor and ORP‑EIS data confirmed the reliability and practical relevance of the method.
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Early Detection and Practical Applications
The system not only tracks initial electrolyte penetration but also detects changes at the coating/metal interface, indicating early stages of corrosion. This allows potential degradation processes to be identified long before visible damage occurs, enabling predictive maintenance and improved lifetime evaluation of protective coatings.
In industrial applications, the new technology could be implemented as an on-site diagnostic tool for continuous monitoring under real conditions. Offering high sensitivity and in-situ capability, it represents an important step toward bridging laboratory research and real-world corrosion performance evaluation.
Source: Jiryaeisharahi, Z. et al. Exploring transport properties and onset of corrosion in organic coated metals using an innovation sensor-based methodology supported by ORP-EIS. Progress in Organic Coatings, Volume 207, 109388 (2025).
