Measurement 122 (2018) 73–81

Contents lists available at ScienceDirect

Measurement
journal homepage: www.elsevier.com/locate/measurement

Development of a portable device for measuring the corrosion rates of T

metals based on electrochemical noise signals
⁎
J.H. Arellano-Péreza, O.J. Ramos Negróna, R.F. Escobar-Jiménezb, , J.F. Gómez-Aguilarc,
J. Uruchurtu-Chavarínd
a
Posgrado del Tecnológico Nacional de México/CENIDET, Int. Internado Palmira S/N, Palmira C.P. 62490, Cuernavaca, Morelos, Mexico
b
Tecnológico Nacional de México/CENIDET, Int. Internado Palmira S/N, Palmira C.P. 62490, Cuernavaca, Morelos, Mexico
c
Conacyt-Tecnológico Nacional de México/CENIDET, Int. Internado Palmira S/N, Palmira C.P. 62490, Cuernavaca, Morelos, Mexico
d
Centro de Investigación en Ingeniería y Ciencias Aplicadas-Universidad Autónoma del Estado de Morelos, Av. Universidad 1001, Col. Chamilpa, C.P. 62209 Cuernavaca,
Morelos, Mexico

A R T I C LE I N FO A B S T R A C T

Keywords: This work deals with the design of a portable device for measuring and monitoring corrosion variables. The
Electrochemical noise measured variables are the electrochemical potential (EP) and electrochemical current (EC). Using these signals
Localization index the localization index (LI) and the corrosion rate (CR) can be estimated. Since electrochemical potential (EP) and
Corrosion rate electrochemical current (EC) are weak signals, an electronic circuit was designed and developed for measuring
Neural network
these two variables. The electronic circuit includes a signal amplifier, a physical filter, and an Analog to Digital
Extreme learning machine
Converter (ADC). To estimate the IL and CR the statistical method and Neural Network method were used and
compared. The device advantages are its low-cost of construction, its portability and the possibility to analyze
the corrosion variables in different materials. Experimental tests carried out using 6061-T6 aluminum shown the
effectiveness of the proposed device and methods and the versatility of the portable device.

1. Introduction
Metals are materials with different characteristics and properties,
such as hardness, malleability, ductility, among others. Because of their
properties metals are widely used in the industry. The metals most
commonly used are steel, zinc, aluminum, and copper, any of this
metals can suffer corrosion. The corrosion is characterized by the metal
destruction, due to the metal exposure to different environmental ag-
gressive agents. These agents include humidity, temperature, air, vapor,
pollutants, etc.
Corrosion is present in most of the metal parts of machinery and
industrial equipment, as well as in pipes and containers of industrial
processes. The corrosion consequences are diverse, some of them are a
reduction of the pipe surfaces thickness, leakage, the presence of pol-
lution substances, or an equipment damage as a result of a leak.
Furthermore, the expenditure of additional costs to repair or replace the
corroded surface must be considered. Corrosion has been the cause of
accidents such as the flight 243 of Aloha Airlines in 1988 ([1]) or the
accident caused by a gas pipe explosion in Guadalajara, Mexico in 1992
([2]).
There are different corrosion types (uniform, general or localized)
some of them are more destructive than others. To identify the corro-
sion type is necessary to estimate the localization index (LI). Knowing
the LI will allow to take preventive actions and prevent any damage
caused by an aggressive corrosion. The corrosion rate must be calcu-
lated to determine the lifetime of metals. The CR can be calculated
using physical or electrochemical methods. In literature, important
works have been reported on the corrosion analysis using the EN
technique [3–5]. Authors in [3] mention that the EN is one of the most
promising in situ electrochemical methods in corrosion and electro-
chemical science.
Nowadays, exists different devices to estimate the corrosion rate
however they are usually expensive for example the PT-6000 corros-
ometer with a price of $1 572.45 USD, the Gill AC potentiostat with a
price of $7 618.72 USD, the Checkmate-1 corrosometer with a price of
$4 649.65 USD, Aquamate corrater with a price of $2 925.24 USD. To
deal with the devices cost different research works have been developed
to propose lower cost devices as an alternative. The authors in [6–8]
presented the development of devices for measuring the EN to estimate
corrosion variables.
The authors in [6] developed a method and apparatus for the
identification of corrosion in metal objects. The method consisted in

⁎
Corresponding author.
E-mail address: esjiri@cenidet.edu.mx (R.F. Escobar-Jiménez).

https://doi.org/10.1016/j.measurement.2018.03.008
Received 8 November 2017; Received in revised form 17 February 2018; Accepted 5 March 2018
Available online 06 March 2018
0263-2241/ © 2018 Elsevier Ltd. All rights reserved.
J.H. Arellano-Pérez et al. Measurement 122 (2018) 73–81

analyzing the statistical distribution of the signals generated between

two electrodes, exposed to the same conditions of the metal object. The
authors used ANNs for the analysis.
A computerized system for real-time monitoring the electrochemical
noise and for estimating the corrosion rate was developed and pre-
sented in [7]. The system was configured to use three electrodes and
one Analog to Digital Converter (ADC) to obtain the electrochemical
noise signals. Once the signals were measured, a computational system
analyzes the signals by statistical parameters (mean value, standard
deviation, variance) to obtain the corrosion rate and corrosion type.
A device for the remote monitoring of the electrochemical corrosion
processes was developed and presented in [8]. The device was config-
ured to use the electrochemical technique for the corrosion levels es-
timation. The device probe used the three nominally identical elec-
trodes configuration. The system works via remote, sending the voltage
and current measures via modem to a computer which realize the signal
processing.
In literature, different works have reported two different electrode
configurations to measure electrochemical noise [9–12]. One of them is
the three identical electrodes configuration, and the other is two Fig. 1. Block diagram of the device.
identical electrodes and one reference electrode usually of a different
material (silver, platinum, titanium, etc.). In the first configuration, one 2. Corrosion device development
of the electrodes is used as a pseudo-reference electrode, this config-
uration is used in the industry for developing field tests, while the The device components are three identical working electrodes (WE),
second configuration is commonly used in laboratory tests. an electronic circuit board for the signals amplification, a single-board
The ANNs have proven to be a good tool in applications where the computer for data analysis, and a touchscreen display. Fig. 1 shows the
system inputs are noisy or incomplete. In different works ANNs have flow diagram of the device operation.
been developed for estimating some corrosion parameters [13–17].
Authors in [13] used an ANN to predict the corrosion rates of
transmissions lines in Brasil. The ANN was developed with a multilayer 2.1. Electrodes
perceptron with ten neurons in the input layer (moisture, rain, wind,
etc.), and two intermediate layers of sigmoid neurons and one output A probe formed by three identical electrodes of 6061-T6 aluminum
neuron with a linear function (purelin) to amplify the received signal to was developed to estimate the corrosion type and the corrosion rate of
the actual corrosion values. The Levenberg–Marquardt back- this metal [18].
propagation algorithm was used for the neural network training. An epoxy resin was used to encapsulate the three electrodes. For
The corrosion behavior of metals and alloys was predicted using a each electrode, one electrode surface was drilled to weld a copper wire
supervised neural network in the data mining presented in [14]. The or use a connector, (Fig. 2 (a))) while the other surface (the surface area
collected data were: metal glass current measurements, corrosion rate exposed to the solution) was polished with grit paper (Fig. 2 (b))),
data on carbon and steel alloys, and grade two titanium current data. washed with distillate water and degreased with acetone according to
The first two groups of data belonged to generalized corrosion and the the ASTM G1-90 [19]. The surface area exposed to the solution was
last to localized corrosion. 0.3156 cm2 . Fig. 2 (c)) shows the probe immersed in a 3.5% NaCl so-
The authors in [15] applied an ANN to predict the behavior of metal lution.
corrosion. The ANN was feedforward multilayer topology 6-7-1. The
clime and pollution variables were used as the ANN inputs. Applying 2.2. System measurement and acquisition
ANNs, the atmospheric corrosion prediction of metals and alloys
(carbon steel, galvanized steel, copper, and aluminum) was carried out To measure the EP and EC the three identical electrodes were used.
in [16]. To measure the current signal a zero resistance ammeter (ZRA) array
The authors in [17] developed a research on the corrosion rate was used and connected to the electrodes WE1 and WE2 (See Fig. 3. To
evaluation of the zirconium-based nano-ceramic layer on galvanized measure the potential, the signal was connected to the electrodes WE1
steel in a 3.5% NaCl solution. The authors used a neural network and and WE2, and WE3 was the reference electrode. To eliminate the
adaptive neuro-fuzzy inference system to develop the study. parasite signals (aliasing) low-pass filters were designed, the cutoff
The problem of using electrochemical noise technique to estimate frequency used was 4 Hz.
the corrosion variables is to measure the potential and current since
they are weak signals. So, these two signals have to be amplified and
filtered. In this work, an electronic circuit was designed and developed 2.3. Single-board computer and touch screen display
for measuring these two variables. The electronic circuit includes a
signal amplifier, a physical filter, and an Analog to Digital Converter A single-board computer was used to develop the portable device
(ADC). for measuring and monitoring corrosion variables, and a touchscreen
As previously mentioned, the corrosion measurement commercial display was used to establish a communication interface and a gra-
devices are expensive, while the corrosion measurement low-cost de- phical interface between the user and the device.
vices presented in the bibliography needs a computer or additional Fig. 4 shows the final version of the portable device called CRE-1 (at
equipment for measuring and processing the EP and EC. the top right side), versus commercial devices. At the bottom left side of
In the present work, the combination of the electrochemical noise Fig. 4, the on–off switch and connectors of the portable device are
technique with the signals conditioning and the signals processing by shown. At the bottom center of Fig. 4, the fan and the supplied source of
means artificial neural networks have resulted in a practical and eco- the CRE-1 are shown. At the bottom right side of Fig. 4 the electronic
nomical device for estimating the LI and the CR. circuit board of the CRE-1 is shown.

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J.H. Arellano-Pérez et al. Measurement 122 (2018) 73–81

(a) Electrode connections. (b) Electrode surface.

(c) Aluminum electrodes inmersed in 3.5%

NaCl.
Fig. 2. Aluminum electrodes.

3. Corrosion estimation

Next, the electrochemical (Section 3.1 and the ANN (Section 3.2
methods are presented. The CRE-1 uses two ANNs to estimate the
corrosion type and corrosion rate. The electrochemical method was
used to validate the ANNs.

3.1. Electrochemical theory

Fig. 3. Block diagram of the amplification circuit. When a metal is in contact with an electrolyte, the corrosion phe-
nomena generates changes in the potential and the current caused by
the reduction reactions. So, electrochemical noise technique uses these
EP and EC changes to describe the corrosion phenomena.
To use the electrochemical noise technique the EP and EC mea-
surements have to be stored and recorded in data sets. Then, the

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J.H. Arellano-Pérez et al. Measurement 122 (2018) 73–81

Fig. 4. Developed device CRE-1.

resistance (Rn) is calculated based on each data set or record. The Rn is k: constant in different units (Table 1).
the relation between the standard deviation of potential noise (σV ) and ρ : metal or alloy density.
the standard deviation of current noise (σI ), Eq. (1). icorr : current corrosion density.
σv Weq: metal or alloy equivalent weight (dimensionless).
Rn = .
σI (1)
The corrosion type can be identified using the corrosion
Another important parameter is the polarization resistance (Rp), Eq. Localization Index (LI) which is calculated with σI and the root mean
(2) square of the current noise (Irms ) [24], Eq. (6). According to Table 2 the
B corrosion type can be classified in localized, mixed and passive or
Rp = ,
icorr (2) uniform. [25].

where icorr is the current corrosion density and B is related to Tafel σI

LI = .
cathodic (βc ) and anodic (βa ) slopes of the system, described by the Eq. Irms (6)
(3) Although the statistical analysis using electrochemical noise data is
βa βc widely used there is disagreement among researchers about the use of
B= .
2.303(βa + βc ) (3) IL as an indicator of the type of corrosion present and hence of the
corrosion mechanism ([26–29]). However, different researchers are in
Many authors have concluded that Rp and Rn are equivalents favor of the IL because of they compare their results with other methods
[11,20–22] therefore Rp is replaced by Rn in Eq. (2) and icorr can be ([30–33]).
obtained, Eq. (4).
B 3.2. Artificial neural networks
icorr = ,
Rn (4)
using the icorr value, the corrosion rate (CR) can be obtained with the This section provides the ANNs methodology to estimate the loca-
Eq. (5) [23]: lization index (LI) and the corrosion rate (CR).
The portable device counts with two artificial neural networks. One
Weq ⎞ ⎞ ANN was trained to estimate the Localization Index, and the second one
CR = k ⎜⎛icorr ⎜⎛ ⎟ ⎟,

⎝ ⎝ ρ ⎠⎠ (5) ANN was trained to predict the CR. Both ANNs are feedforward type
with one hidden layer, inputs and outputs of the hidden layers are
where
weighted. The ANNs inputs are the standard deviation of the potential

Table 1
Table 2
Values of k for the CR calculus.
LI value ranges.
Units Values of k
Corrosion type LI values
CR i corr ρ k
Max. Min.
mpy μ A/cm2 g/cm3 mpy g/μ A cm 0.1288
Localized corrosion 1.0 0.1
mm/year A/m2 kg/m3 mm kg/A m year 327.20 Mixed corrosion 0.1 0.01
mm/year μ A/cm2 g/cm3 mm g/μ A cm year 3.27 × 10−3 Uniform corrosion 0.01 0.001

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J.H. Arellano-Pérez et al. Measurement 122 (2018) 73–81

Fig. 5. ANN architecture.

and the standard deviation of the current. The hidden layer had 15 an experimental current noise dataset. Each dataset contained 3000
neurons. The ANNs architecture is described in Fig. 5. data. The ANNs training was carried out for the CRE-1 as well as the
The Extreme Learning Machine (ELM) algorithm was used for ANNs commercial devices. The datasets were begins sampled when the cor-
training [34]. Defining the training data set as rosion measurements reached the steady state (after two hours of the
D = (x i,ti )|x i ∈ Rn,ti ∈ Rm,i = 1,…,N , one activation function g (x ) and a electrodes immersion in a 3.5% NaCl solution). It is important to
∼
hidden layer of N neurons. Where N is the number of data for neural mention that the experimental tests between the CRE-1 and the com-
training, x i are the inputs and ti the desired outputs, the training is mercial devices didn’t carry out simultaneously. So, small variations in
described in the next steps: the variables predictions may occur.

Step 1: Random assignment of the input weighs wi and the bias
∼
bi,i = 1,…,N .
Step 2: Calculation of the matrix H of the output of the hidden layer
where
H (w1,…,w N∼,b1,…,b ∼
N ,x1,…,xN )
⎡ g (w1·x1 + b1) ⋯ g (w N ·x1 + b N ) ⎤
∼ ∼
=⎢ ⋮ ⋯ ⋮ ⎥ . are shown in the following figures.
⎢ g (w ·x + b ) ⋯ g (w ∼·x + b ∼) ⎥ ∼
⎣ 1 N 1 N N N ⎦N × N
Step 3: Calculation of the output weights β
β = H+T,
where H+ is the generalized inverse of Moore–Penrose commonly
known like pseudo-inverse and T contains the desired outputs
T = [t1,…,tN ]T .
The input weighs (w), the bias (b) and the output weighs (β ) are
obtained with the neural network training, then the neural network
output y is calculated with the following equation
y = Hβ.
4. Results
4.1. Testing the device and the ANNs
The measures obtained from the CRE-1 were used to compare its
performance versus two commercial devices. One commercial multi-
meter(Keysight™ model 34461A) was used to measure the current noise
and the second one (Agilent™ 34410A) was used to measure the po-
tential noise. A LabVIEW™ interface was used to record the data of the
two multimeters and save the data in a text file. Two artificial neural
networks were implemented to develop the performance comparison
between the CRE-1 device and the commercial devices. As mentioned
previously, the LI and the CR are estimated by each one of them. Both
ANNs were trained using an experimental potential noise dataset and
4.2. Electrochemical measurements for training and test the ANNs
The tests were carried out by measuring the potential and current
from the 6061-T6 aluminum electrodes immersed in a 3.5% NaCl so-
lution. The measures were recorded using the sampling time of one
second per sample having a total record of 27,270 data (7 h 35 min).
The experimental measures of the commercial devices and the CRE-1,
Fig. 6 shows the potential noise measurement comparison between
the commercial device and the CRE-1 and Fig. 7 shows the current noise
measurement comparison between the commercial device and the CRE-
1.
(7) The level of the signals generated by the corrosion processes is
higher than the level of the thermal (Johnson) noise processes signals
[35]. In this sense, it is possible to ensure that the monitored signals
correspond to a corrosion process.
4.3. Training of the ANNs
For each artificial neural network training, 27,270 data were di-
vided into 2727 records of 10 samples each one. These records were
used to calculate the standard deviation of current (σI ), the standard
(8)
deviation of voltage (σV ), and be able to estimate by means the statis-
tical method the Corrosion Rate (CR), and the Localization Index (LI).
Once obtained the CR and the LI the training inputs were CR,σI and σV
for one ANN. And LI ,σI and σV for the other. The ANN design has 15
neurons in the hidden layer, and the activation function was the hy-
perbolic tangent function.
The training errors (Root Mean Square Error) with 100,000 epochs,
were 0.1288 for the CR approximation (Fig. 8) and 0.0042 for the LI
approximation (Fig. 9). The obtained bias, weighs and thresholds were
saved to test the networks.
As a result of the device development and the implementation of the
neural networks, it is possible to estimate every ten seconds the alu-
minum CR and the corrosion LI. Fig. 10 shows the corrosion rate cal-
culation using the statistical method (blue1 line) and the corrosion rate
estimated by the ANN (red line) of the 3000 data measured, the error
between both methods was 0.5627.

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J.H. Arellano-Pérez et al. Measurement 122 (2018) 73–81

Fig. 6. Potential noise measurement of 6061-T6 aluminum inmersed in 3.5% NaCl.

Fig. 7. Current noise measurement of 6061-T6 aluminum inmersed in 3.5% NaCl.

Fig. 8. Training of the ANN for corrosion rate estimation.

Fig. 11 shows the comparison between the CR obtained with the
multimeter data using the statistical method (blue line) and the CR
obtained with the developed device data using the ANN (red line).
Fig. 12 shows the LI estimation using the statistical method (blue
line) and the localization index estimated by the ANN (red line) of the
1
For interpretation of color in Figs. 10–13, the reader is referred to the web version of
this article.
3000 data measured, the error between both methods was 0.0017.
Fig. 13 shows the comparison between the LI obtained with the
multimeter data using the statistical method (blue line) and the LI ob-
tained with the device data using the ANN (red line).
The LI reported in almost all cases was mixed-type corrosion with a
slight tendency toward passivation.

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J.H. Arellano-Pérez et al. Measurement 122 (2018) 73–81

Fig. 9. Training of the ANN for localization index estimation.

Fig. 10. Testing the ANN for CR estimation with data of aluminum inmersed in 3.5% NaCl.

Fig. 11. Comparison between the CR obtained by the multimeters and the device.

5. Discussion statistical analysis.

Two ANNs were implemented to estimate the metal’s CR and LI,
each implemented ANN has two inputs (σV and σI ), a hidden layer with
15 neurons and an output neuron that estimates the CR or the LI. The
activation function was the hyperbolic tangent function. The corrosion
rate estimation obtained by the ANN was similar than the obtained by
The device can perform a statistical analysis as well as ANN esti-
mation of corrosion variables. The statistical analysis is carried out from
the electrochemical data (potential noise and current noise) taking into
account the metal characteristics (density and equivalent weight) to
calculate the CR (in mm/year) and the corrosion type. When the ANNs
are used only is necessary the electrochemical data for the ANN

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J.H. Arellano-Pérez et al.
Fig. 12. Testing the ANN for LI estimation with data of aluminum inmersed in 3.5% NaCl.
Fig. 13. Comparison between the LI obtained by the multimeter and the device.
training, in order to estimate the metal’s CR and LI.
Using the multimeter measures, the CR calculated average value
was 0.4207 mm/year. While using the CRE-1 measures, the CR esti-
mated average value was 0.3703 mm/year. Considering a thickness of
five millimeters the metal’s useful lifetime is 11.8 years according to the
estimation using the multimeters data and 13.5 years according to the
neural network estimation. Also, the methods comparison (ANNs and
statistical) showed slight differences between the estimation of the CR.
6. Conclusions
A device for measuring metal corrosion rates (6061-T6 aluminum)
was developed by recording and analyzing the EN data generated when
a metal comes into contact with an electrolyte.
The developed device is economical compared to commercial po-
tentiostats or corrosometers, which in addition to having a high cost
they require a computer or there are difficult to handle or move to the
testing area. In addition to providing online information, the CRE-1 also
saves the records made since they could be required for further analysis
or collect them as a history.
Acknowledgments
José Hugo Arellano Pérez and Oscar Jaime Ramos Negrón would
like to thank to CONACYT (Consejo Nacional de Ciencia y Tecnología
de México) for the support given during the development of their Ph.D’s
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Measurement 122 (2018) 73–81
thesis. The authors would like to thank PRODEP, Tecnológico Nacional
de México and CENIDET for the support to develop this work. José
Francisco Gómez Aguilar acknowledges the support provided by
CONACyT: cátedras CONACyT para jovenes investigadores 2014.
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