Coustomed Flexible silicone Electrical Resistance (ER) corrosion rate sensors
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Flexible silicone Electrical Resistance (ER) corrosion rate sensors represent an advanced class of corrosion monitoring technology designed to measure real-time material degradation in high-curvature, restricted, or uneven spaces. By pairing thin, conformable metal elements with resilient silicone or polymer backings, these sensors bend directly to the contours of structural components while delivering instant data on metal thinning via changes in electrical resistance.
How Flexible Silicone ER Sensors Work
- Electrical Resistance Principle: The sensor tracks cumulative metal loss by monitoring electrical resistance. As the exposed metal sensing element corrodes and thins, its cross-sectional area decreases, causing electrical resistance to rise.
- Temperature Compensation: Resistance changes naturally with ambient temperature shifts. To prevent false readings, these sensors mount an identical reference electrode on the same substrate. This reference element is shielded by a protective, anti-corrosion barrier (like silicone or epoxy) so it records only temperature deviations.
- Silicone/Polymer Substrate: Unlike traditional rigid, screw-in ER Probe, these utilize ultra-thin base materials (often between 125µm and 0.5 mm thick). This makes the sensor completely flexible, allowing it to curve around pipes, flanges, or complex joints
Primary Industry Applications
- Corrosion Under Insulation (CUI): A critical application is monitoring steel pipelines and vessels covered by thermal insulation. These flexible bands wrap smoothly beneath insulation layers to capture condensation-induced degradation early.
- Flanges and Complex Joints: Standard sensors cannot sit flush against tight bends. Thin-film flexible ER sensors fit inside flange leak covers or wrap tightly against irregular elbow joints.
- Vapor and Non-Conductive Streams: Unlike Linear Polarization Resistance (LPR) methods which require a conductive liquid electrolyte (like water), ER technology functions reliably in non-conductive environments, including dry gases, vapors, crude oil, and soils
Core Advantages vs. Rigid Alternatives
| Feature | Flexible ER Sensors | Traditional Rigid ER Probes |
| Geometry | Conformable; wraps closely around curved structures. | Rigid, threaded, or flanged plug design. |
| Contact Layer | Direct, flush surface placement captures real pipeline skin conditions. | Intrusive or perpendicular placement inside processing streams. |
| Profile | Ultra-thin profile (< 0.5mm), perfect for tight clearances. | Bulky profile, requiring dedicated access fittings. |
| Installation | Non-intrusive surface mounting; rarely requires process shutdowns. | Often requires custom hot-tapping or specialized access machinery. |
We support the realization of functional elements through:
- Functional thin-film material, process and structure design
- Thin-film device fabrication on customer substrates
- Assessment of corrosion rate accuracy
