Small Ultrasound-Based Corrosion Sensor for Intraday Corrosion Rate Estimation

The conventional way of studying corrosion in marine environments is by installing corrosion coupons. Instead, this paper presents an experimental field study using an unattended corrosion sensor developed on the basis of ultrasound (US) technology to assess the thickness loss caused by general atmospheric corrosion on land close to the sea (coastal region). The system described here uses FPGA, low-power microcontroller, analog front-end devices in the sensor node, and a Beaglebone black wireless board for posting data to a server. The overall system is small, operates at low power, and was deployed at Gran Canaria to detect the thickness loss of an S355 steel sample and consequently estimate the corrosion rate. This experiment aims to demonstrate the system’s viability in marine environments and its potential to monitor corrosion in offshore wind turbines. In a day, the system takes four sets of measurements in 6 hour intervals, and each set consists of 5 consecutive measurements. Over the course of 5 months, the proposed experiment allowed for us to continuously monitor the corrosion rate in an equivalent corrosion process to an average thickness loss rate of 0.134 mm/year.