Copper corrosion testing to assess industrial product compatibility
What was the challenge or problem to be solved?
Corrosion of metallic materials is one of the most critical factors in the reliability and durability of industrial equipment, piping, and systems. In environments where materials come into continuous contact with liquid process products, even minor chemical incompatibilities can lead to progressive degradation, premature failure, or safety issues that are difficult to detect in the short term. In this context, the need arose to evaluate the behavior of a liquid product in relation to components made of copper, a material widely used for its conductivity and mechanical properties, but sensitive to certain corrosive agents.
Corrosion testing on copper under real conditions of use
The starting point for the project was the need to analyze whether a liquid process product could cause corrosion in copper components present in industrial facilities, such as equipment, storage systems, or pipes. The objective was not only to identify the presence of chemical attack, but to do so in a representative manner, reproducing controlled conditions of contact, temperature, and exposure time similar to those that occur in service.
This type of copper corrosion test is particularly relevant in product validation phases, formulation changes, or preventive studies, as it allows problems to be anticipated before they result in breakdowns, production stoppages, or high maintenance costs. The customer was looking for a clear and objective answer that would enable them to make informed technical decisions about the safe use of the product in their facilities.
Assessment of corrosive potential to prevent premature failures
The main objective of the project was to carry out an assessment of the corrosive potential of the liquid product, determining whether its interaction with copper could cause significant deterioration of the material. This assessment was intended to enable the degree of corrosion to be classified in a comprehensible manner, based on standardized and comparable visual criteria, avoiding subjective interpretations.
From the customer’s point of view, the value of the study lay in the “why”: to have a solid technical basis for preventing premature corrosion failures, ensuring product compatibility with existing materials, and reducing medium- and long-term operational risks. It was not an academic analysis, but a practical tool for industrial decision-making.
Custom corrosion testing in the absence of standard equipment
The main challenge of the project arose when it was found that there was no standard commercial equipment available to perform the test directly. Although there are standardized methods and guidelines for copper strip corrosion, the specific characteristics of the product and the required test conditions made the use of conventional solutions unfeasible.
This scenario presented a twofold complexity. On the one hand, it was necessary to design a system that would ensure proper immersion and contact of the copper with the liquid, while maintaining control of the critical variables of the test. On the other hand, it was necessary to ensure that the procedure was repeatable, traceable, and aligned with regulatory criteria, so that the results obtained would be reliable and comparable.
In this context, INFINITIA played a key role, contributing its expertise in forensic engineering applied to testing and in the development of experimental methodologies adapted to real products, even when no standard solutions are available.
How was it addressed, or what was the solution?
Once the challenge and objective of the project had been defined, the strategy focused on designing a testing approach that combined technical rigor, experimental flexibility, and clarity in the results, while always maintaining the focus on the final value for the customer.
Corrosion testing adapted to the product through experimental engineering
The project began with a thorough review of the technical and regulatory information applicable to corrosion testing, as well as the context of use of the product being evaluated. This preliminary analysis made it possible to define the evaluation criteria, exposure conditions, and key parameters to be monitored during the test.
On this basis, a product-specific corrosion test was chosen, in which the method is tailored to the actual characteristics of the liquid and the metal material, rather than forcing the product into a standard test that is not very representative. This approach is particularly relevant in industrial environments, where products do not always fit into closed laboratory protocols.
Custom corrosion testing performed by the INFINITIA team
The INFINITIA team designed and prepared a custom experimental setup, selecting materials, containers, and auxiliary systems that would allow the test conditions to be reproduced in a controlled manner. This experimental engineering work was crucial in ensuring the validity of the study.
Once the assembly was prepared, the corrosion test was carried out under controlled conditions, ensuring the stability of critical variables and the correct interaction between the copper and the liquid product. The approach applied yielded consistent results, even in a non-standard scenario, demonstrating INFINITIA’s ability to perform customized corrosion tests with quality criteria and technical rigor.
Throughout the process, the team played a key role in planning, executing, and supervising the trial, ensuring that each phase met the defined objectives and the client’s actual needs.
Classification of the degree of corrosion and value added for the customer
After completing the test, the surface condition of the copper was evaluated through visual inspection and comparison with standardized reference guides. This phase allowed for clear classification of the degree of corrosion observed, facilitating objective interpretation of the results.
The main benefit of the project was that the client obtained a clear technical response regarding the compatibility of the product with copper components, enabling them to make informed decisions about its use, minimize risks, and reinforce the reliability of their facilities. In addition, the study highlighted the value of having a technical partner capable of adapting testing methods to real-life situations, where methodological flexibility is as important as the result itself.
This success story demonstrates how, through forensic engineering and material life testing, INFINITIA provides practical solutions to complex industrial problems, even when there are no standard tools available to address them.
