Ultrasound Corrosion Mapping on Hot Stainless Steel Surfaces

This study investigates the application of Phased Array Corrosion Mapping (PACM) as a non-destructive testing (NDT) method for detecting and monitoring corrosion growth on hot stainless steel (SS) surfaces, specifically focusing on SS 304 and SS 316. Conducted across a temperature range of 30 °C to 250 °C, the research evaluates the effectiveness of PACM in high-temperature environments typical of the petrochemical industry. Experiments were conducted using specimens with machined slots and flat-bottom holes (FBHs) to simulate corrosion defects. The results demonstrate that PACM effectively detects and maps corrosion indicators, with color-coded C-scan data facilitating easy interpretation. Temperature variations significantly influenced ultrasound signal characteristics, leading to observable changes in FBH indications, particularly at elevated temperatures. Increased ultrasound attenuation necessitated adjustments in decibel settings to maintain accuracy. SS 304 and SS 316 exhibited distinct responses to temperature changes, with SS 316 showing higher dB values and unique signal behaviors, including increased scattering and noise echoes at elevated temperatures. Detected depths for slots and FBHs correlated closely with designed depths, with deviations generally less than 0.5 mm; however, some instances showed deviations exceeding 2 mm, underscoring the need for careful interpretation. At temperatures above 230 °C, the disbanding of probe elements led to weak or absent signals, complicating data interpretation and requiring adjustments in testing protocols. This study highlights the feasibility and effectiveness of PACM for corrosion detection on hot SS surfaces, providing critical insights into material behavior under thermal conditions. Future research should include physical examination of samples using Scanning Electron Microscopy (SEM) to validate and enhance the reliability of the findings. The integration of non-contact NDT methods and optimization of calibration techniques are essential for improving PACM performance at elevated temperatures.