Special Testing

Special Testing

MATCO has accumulated decades of testing experience with a broad range of materials. Testing usually involves subjecting the client’s material to some special environment. This can include a pre-determined mechanical stress, perhaps applied repetitively to monitor the development of fatigue failure. The chemistry of the environment will probably be controlled, including perhaps cyclic wetting and drying, possibly including also exposure to pH extremes. Other exposure conditions include the typical salt-spray environments for testing paints, other coatings and metals.

A special skill-set of MATCO’s NACE certified corrosion technicians includes the applications of electro-chemical principles to corrosion testing. This involves the measurement and recording of minute flows of current in metal samples, indicating to what degree corrosion is taking place and driving that corrosion forward or backward. This can be used to measure extremely thin oxide coatings and to determine the local tendencies of the materials to corrode.

MATCO has constructed a controlled atmosphere chamber in which minute concentrations of mixed flowing gases (MFG) can be made to bath the samples to mimic atmospheric conditions in operating environments. This “mixed flowing gas” system is almost unique among independent testing labs.

As an example of the range of tests applied to client projects, a major national pharmaceutical firm recently asked MATCO to compare the durability of the label materials supplied to them by eleven different manufacturers. One might expect some uniformity of such products, but the client wanted to rank them. MATCO devised a series of tests to determine the durability/resistance of the materials to pure heat (as in the glove compartment of your car), heat plus moisture (as in your bath room under a heat lamp), UV radiation (as on the dashboard of your car) and in contact with atmospheric pollutants (perhaps beneath your bathroom sink).

In addition, all the products were tested in resistance to nine common bathroom chemicals. The results of these stiff tests were most interesting: no one of the label products performed outstandingly in all areas. Each fell down in one or more areas. However, a weighted ranking was created so that the client could return to their suppliers and show them where they could improve their performance.

This story is typical of many in which no industry standard tests exist and MATCO has to create a protocol agreeable to the client, then build the equipment to perform the tests.

The investigation of complex corrosion failures may require multidisciplinary testing and analysis to determine the root cause of failure. The end determination must be made with a high degree of certainty to assure that proper replacement materials are selected and that the most effective corrosion control methods are used.

At MATCO, we specialize in conducting corrosion testing and failure analysis investigations. This requires not only a laboratory that features state of the art equipment, but a multidisciplinary professional staff as well. The Corrosion Testing and Product Development Laboratory, located in Pittsburgh , Pennsylvania , has been in existence since 1993 and is one of the premier corrosion testing and inspection facilities in the Northeast. The four primary functions are:

• Materials Evaluation, Selection and Testing
• Laboratory and Field Evaluation
• Corrosion  Protection Design, Inhibitors and Monitoring
• Materials Research and Development

The Corrosion Testing and Product Development Laboratory at MATCO boasts high tech instrumentation that includes computerized Corrosion Electrochemical Testing Equipment (AC And DC), Accelerated Corrosion Testing Equipment, Environmental (CF and SCC) Corrosion Testing Equipment, Alternate and Immersion Testing Equipment, Cabinet Testing and Mixed Flow Gas testing equipment. As every good scientist knows, having the right tools is half the battle in providing accurate and reliable test results to the client.

Figure 1-Electrochemical Polarization and Microstrcutral Characteristics of two Types of Coatings (Alonized & Chromatized) . Chromatized coating exhibits superior  corroion resistance in this application.

The other half of the battle is having the right staff. At MATCO the Corrosion Division staff includes NACE (National Association of Corrosion Engineers) Certified Corrosion Engineers, Materials Selection/Design, Coatings and Cathodic Protection Specialists, Materials Scientists, Professional Engineers, Metallurgists, Polymer Scientists, Chemists, and Paint and Coating specialists. By combining the right equipment with the right staff, determinations of the root cause can be made.

MATCO's other capabilities include metallurgical investigations; R&D of new products or improvements to existing products, inspectors for onsite investigations and third party inspections, one to two day seminars on materials selection, corrosion, coating and failure analysis, and litigation support. We can also perform a wide array of routine NACE and ASTM test procedures for evaluating the corrosion resistance of metallic and non-metallic materials and components in adverse environments. If necessary, MATCO personnel can be on site within 48 hours when requested during emergency situations.

At MATCO, we provide you with a laboratory that you can count on. We deliver accurate and reliable test results and root cause determinations on which future materials selection and corrosion control decisions can be based.

Who performs the investigation:

Our team includes Certified Metallurgical/Corrosion / Cathodic Protection/ Materials Selection/ Design / Grease/ Lubricant/Coating Specialists and FEA specialists:

Dr. Zee                                       Dr. Gibbon

Dr. Bayer                                    Dr. Bavarian

Mr. Groll                                     Mr. Gretz

Mr. Larkin                                   Dr. Kasraie

Ms. Riley

Specialists in Corrosion Engineering & Failure Analysis

Experienced PE, PhD Scientists, NACE Certified in Corrosion, Coating, Design , Materials Selection & Cathodic Protection Specialists who will solve your corrosion problems at both initial design stages and in service. We have been providing corrosion engineering services for over 3000 clients.

• Corrosion Engineering and Cathodic Protection of Production /Transmission Facilities: (a) Underground (b) Above Ground (c) Marine Environments
• Corrosion Evaluation, life expectancy determination and cathodic protection of electrical poles and transmission lattices
• Corrosion mapping, detection of "Hot Spots", cathodic protection of reinforced concrete structures
• Explosions/Fire Investigation forensic engineering
• Electrochemical EIS , DC and AC Testing - Determination of cathodic protection criteria for non-ferrous alloys and stainless steels
• On-site Evaluation of tanks and corrosion mitigation by protective coatings and internal or external Cathodic Protection
• Corrosivity determination of soil, water and determination of corrosion mitigation techniques
• On-site coating evaluation and selection of coatings for specific corrosive environments by EIS technique