J. Mater. Sci. Technol. ›› 2020, Vol. 53: 146-162.DOI: 10.1016/j.jmst.2020.04.033
• Invited Review • Previous Articles Next Articles
Da-Hai Xiaa,b,*(
), Shizhe Songa,b(), Lei Taoc(), Zhenbo Qina,b,*(), Zhong Wua,*(), Zhiming Gaoa,b(), Jihui Wanga,b(), Wenbin Hua,b(), Yashar Behnamiand(), Jing-Li Luod,**()
Received:2020-03-24
Revised:2020-04-19
Accepted:2020-04-26
Published:2020-09-15
Online:2020-09-21
Contact:
Da-Hai Xia,Zhenbo Qin,Zhong Wu,Jing-Li Luo
About author:Dr. Da-Hai Xia is a teacher at the school of Materials Science and Engineering, Tianjin University. He received his PhD degree from Tianjin University (China) in 2012. He then joined the University of Alberta (Canada) as a Postdoctoral fellow (2013-2014) under the guidance of Prof. Jing-Li Luo. His research interests are interdisciplinary studies of corrosion, electrochemistry and surface science.|Zhenbo Qin is a lecturer in the School of Materials Science and Engineering at Tianjin University. He received his Ph. D. in materials science and engineering from Shanghai Jiao Tong University in 2018. His current research focuses on corrosion mechanism and surface engineering for metallic materials.|Dr. Yashar Behnamian is an industrial postdoctoral research fellow at University of Alberta, Edmonton, Alberta. He obtained his Ph.D. degree in Material Science and Engineering from University of Alberta, Edmonton, Canada in 2015. He was awarded graduate heritage award in 2011. His research has been focused on corrosion mechanism and protection of metallic and non-metallic material in harsh environment.|Dr. Jing-Li Luo is a professor Emeritus at Department of Chemical and Materials Engineering, University of Alberta, Canada. She obtained her Ph.D. degree in Materials Science and Engineering from McMaster University, Canada in 1992. She served as Canadian Research Chair in Alternative Fuel Cells from 2004 to 2015, and received a number of awards including Morris Cohen Award in 2002, McCalla Professorship of University of Alberta in 2003 and Metal Chemistry Award in 2014. Dr. Luo was elected to be Fellow of the Canadian Academy of Engineering in 2016. Her research has been focused on fuel cells, energy storage research, clean energy technology and corrosion control.
Da-Hai Xia, Shizhe Song, Lei Tao, Zhenbo Qin, Zhong Wu, Zhiming Gao, Jihui Wang, Wenbin Hu, Yashar Behnamian, Jing-Li Luo. Review-material degradation assessed by digital image processing: Fundamentals, progresses, and challenges[J]. J. Mater. Sci. Technol., 2020, 53: 146-162.
Fig. 1. Images based on radiation from the electromagnetic (EM) spectrum and acoustic waves: (a) the EM spectrum arranged according to energy per photon [53], (b) an example of infrared photography of steel corrosion under an organic coating [19], (c) the image in (b) obtained from an optical microscope [19], (d) an example of X-ray tomography of corrosion pits [59], (e) an image of blisters on a lacquered food can, (f) a scanning acoustic microscope (SAM) image of the image in (e) clearly showing the blisters [55], (g) a corrosion pit observed by a scanning electron microscope [55].
Fig. 2. An image processing interface processed in MATLAB? to evaluate atmospheric corrosion in a non-ferrous metal; our group, 2003 (reprinted with permission from Ref. [124]).
| Material | Environment | Corrosion form | Image acquiring devices for the | Image processing methods | Image parameters | Accuracy of image parameters | Other methods | Refs. |
|---|---|---|---|---|---|---|---|---|
| Mild steel Stainless steel | - | Uniform corrosion of mild steel; pitting crevice corrosion in stainless steel; fretted corrosion steel surface; Intergranular SCC of an Inconel heat exchanger tube | Optical microscope (magnification range is from 50 to 500) | Interpretation of HIV model Co-occurrence matrix | Probabilistic identification, Pattern recognition theory for automated classification of surface corrosion damage | Qualitative | - | [ |
| Q235B | Zhoushan marine atmosphere, China | Uniform corrosion | Digital camera (Nikon D50) | Histograms of grayscale, Wavelet transform, fuzzy Kolmogorov-Sinai entropy | Average gray levels Wavelet energy distribution | Semiquantitative | Weight loss | [ |
| Q235B | Zhoushan marine atmosphere, China | Uniform corrosion | Digital camera (Nikon D50) | Fuzzy Kolmogorov-Sinai entropy | K-S entropy | Semiquantitative | Weight loss | [ |
| Q235B | Salt spray corrosion test chamber (spray solution contains 0.1 mol/L NaCl), 30 ℃, relative humidity 70 %. | Uniform corrosion | VHX-2000C microscope (Keyence, Japan) | Wavelet packet based image analysis | Shannon entropy Energy of sub-image | Semiquantitative | Weight loss | [ |
| AISI 1040 steel | H2S solution containing chloride ions | Inverted optical microscope (Opton model TNM-07T-PL) | HSV color model | H, S and V value | Qualitative | Polarization curve | [ | |
| Stonework | Corrosion damage | Fiber optics microscope and digital camera. | Segmentation algorithm | - | Qualitative | - | [ | |
| Ti-6Al-4 V and Al | Al: in a cyclic Salt-Spray testing during 48 h at 35±1 °C; Ti-6Al-4V: immersed in 5% NaCl solution for 180 days at 40±2 °C | Pitting corrosion | Light microscopy | Binary fill hole operation geometry analysis | Area-Box parameter; Pit elongation parameter; roundness parameter; Perimerter ratio | Qualitative | - | [ |
| Pipe | - | Pitting corrosion | Laser scan system laser displacement sensor | Singe-frame super resolution method Markov random field | - | - | - | [ |
| Ti-6Al-4V | 5% NaCl solution for 180 days at 21±2 °C | Pitting corrosion | Light microscopy (LM) and SEM-EDS combined techniques | Gray-level threshold Holes removal by ‘Fill Holes’ filtering Watershed filtering | Area-Box parameter; Pits statistics | Qualitative | - | [ |
| Alloy 800 | NaCl Na2S2O3 | Pitting corrosion | VHX-2000C microscope (Keyence, Japan) | Binary | Pitted area Pitted number | Quantitative | Potentiostatic polarization | [ |
| electroless nickel immersion gold | SO2 atmospheric corrosion | Pitting corrosion | Grayscale distribution calculation; thresholded | Distribution location parameter, scale parameter | - | - | [ | |
| Internal pipeline (with 6 in. inner diameter) | The location of holes and defects on the internal surface of pipes | laser-generatedring | An intensity extraction Algorithm | - | Qualitative | - | [ | |
| High strength aluminum alloys | natural atmosphere in the Test Station of Atmospheric Corrosion in Beijing | KH3000 digital video-microscope system (Hirox. Co. Ltd.) | Wavelet transformation | Wavelet energy distribution | Semiquantitative | - | [ | |
| Aluminum alloy | Simulated artificial rain solution (dry-rain- wet cycle) | Localized corrosion | KH3000 digital video-microscope system (Hirox. Co. Ltd.) | Wavelet transformation | Wavelet energy distribution | Semiquantitative | - | [ |
| T91 steel | Zhoushan marine atmosphere, China | Pitting corrosion | Digital camera (Nikon D50) | Histograms of grayscale, Wavelet transform, fuzzy Kolmogorov-Sinai entropy | Average gray levels Wavelet energy distribution | Semiquantitative | Pit depth measurement | [ |
| Alloy 146, 279, 900, and 926 | H2SO4 + KSCN solution | Intergranular corrosion | Scanning electron microscopy | Bac K-S cattered electron images (phase identification) | - | Semiquantitative | Electrochemical potentiokinetic reactivation tests | [ |
| Shipboard ballast tanks | Coating degradation, regions of potential rust and the spatial distribution of rust | Digital video recorder | Wavelet based de-noising method Wavelet edge detection methods | - | Qualitative | - | [ | |
| Four different primers applied to steel substrates | Accelerated laboratory and outdoor exposure tests | Quality of paints | Conventional scanner | Gray color scale histograms Principal component analysis Hierarchical cluster analysis | - | Qualitative | - | [ |
| Three different polyurethane coating | Marine splash zone, marine atmospheric zone | Coating degradation | Digital camera (Nikon D40) | HSV model | Color | Qualitative | - | [ |
| Alloy 600 | Tetrathionate solution | SCC | CCD camera | Binary | - | Quantitative | Acoustic Emission and Electrochemical Noise | [ |
Table 1 Image processing methods and parameters used to evaluate material corrosion and degradation.
| Material | Environment | Corrosion form | Image acquiring devices for the | Image processing methods | Image parameters | Accuracy of image parameters | Other methods | Refs. |
|---|---|---|---|---|---|---|---|---|
| Mild steel Stainless steel | - | Uniform corrosion of mild steel; pitting crevice corrosion in stainless steel; fretted corrosion steel surface; Intergranular SCC of an Inconel heat exchanger tube | Optical microscope (magnification range is from 50 to 500) | Interpretation of HIV model Co-occurrence matrix | Probabilistic identification, Pattern recognition theory for automated classification of surface corrosion damage | Qualitative | - | [ |
| Q235B | Zhoushan marine atmosphere, China | Uniform corrosion | Digital camera (Nikon D50) | Histograms of grayscale, Wavelet transform, fuzzy Kolmogorov-Sinai entropy | Average gray levels Wavelet energy distribution | Semiquantitative | Weight loss | [ |
| Q235B | Zhoushan marine atmosphere, China | Uniform corrosion | Digital camera (Nikon D50) | Fuzzy Kolmogorov-Sinai entropy | K-S entropy | Semiquantitative | Weight loss | [ |
| Q235B | Salt spray corrosion test chamber (spray solution contains 0.1 mol/L NaCl), 30 ℃, relative humidity 70 %. | Uniform corrosion | VHX-2000C microscope (Keyence, Japan) | Wavelet packet based image analysis | Shannon entropy Energy of sub-image | Semiquantitative | Weight loss | [ |
| AISI 1040 steel | H2S solution containing chloride ions | Inverted optical microscope (Opton model TNM-07T-PL) | HSV color model | H, S and V value | Qualitative | Polarization curve | [ | |
| Stonework | Corrosion damage | Fiber optics microscope and digital camera. | Segmentation algorithm | - | Qualitative | - | [ | |
| Ti-6Al-4 V and Al | Al: in a cyclic Salt-Spray testing during 48 h at 35±1 °C; Ti-6Al-4V: immersed in 5% NaCl solution for 180 days at 40±2 °C | Pitting corrosion | Light microscopy | Binary fill hole operation geometry analysis | Area-Box parameter; Pit elongation parameter; roundness parameter; Perimerter ratio | Qualitative | - | [ |
| Pipe | - | Pitting corrosion | Laser scan system laser displacement sensor | Singe-frame super resolution method Markov random field | - | - | - | [ |
| Ti-6Al-4V | 5% NaCl solution for 180 days at 21±2 °C | Pitting corrosion | Light microscopy (LM) and SEM-EDS combined techniques | Gray-level threshold Holes removal by ‘Fill Holes’ filtering Watershed filtering | Area-Box parameter; Pits statistics | Qualitative | - | [ |
| Alloy 800 | NaCl Na2S2O3 | Pitting corrosion | VHX-2000C microscope (Keyence, Japan) | Binary | Pitted area Pitted number | Quantitative | Potentiostatic polarization | [ |
| electroless nickel immersion gold | SO2 atmospheric corrosion | Pitting corrosion | Grayscale distribution calculation; thresholded | Distribution location parameter, scale parameter | - | - | [ | |
| Internal pipeline (with 6 in. inner diameter) | The location of holes and defects on the internal surface of pipes | laser-generatedring | An intensity extraction Algorithm | - | Qualitative | - | [ | |
| High strength aluminum alloys | natural atmosphere in the Test Station of Atmospheric Corrosion in Beijing | KH3000 digital video-microscope system (Hirox. Co. Ltd.) | Wavelet transformation | Wavelet energy distribution | Semiquantitative | - | [ | |
| Aluminum alloy | Simulated artificial rain solution (dry-rain- wet cycle) | Localized corrosion | KH3000 digital video-microscope system (Hirox. Co. Ltd.) | Wavelet transformation | Wavelet energy distribution | Semiquantitative | - | [ |
| T91 steel | Zhoushan marine atmosphere, China | Pitting corrosion | Digital camera (Nikon D50) | Histograms of grayscale, Wavelet transform, fuzzy Kolmogorov-Sinai entropy | Average gray levels Wavelet energy distribution | Semiquantitative | Pit depth measurement | [ |
| Alloy 146, 279, 900, and 926 | H2SO4 + KSCN solution | Intergranular corrosion | Scanning electron microscopy | Bac K-S cattered electron images (phase identification) | - | Semiquantitative | Electrochemical potentiokinetic reactivation tests | [ |
| Shipboard ballast tanks | Coating degradation, regions of potential rust and the spatial distribution of rust | Digital video recorder | Wavelet based de-noising method Wavelet edge detection methods | - | Qualitative | - | [ | |
| Four different primers applied to steel substrates | Accelerated laboratory and outdoor exposure tests | Quality of paints | Conventional scanner | Gray color scale histograms Principal component analysis Hierarchical cluster analysis | - | Qualitative | - | [ |
| Three different polyurethane coating | Marine splash zone, marine atmospheric zone | Coating degradation | Digital camera (Nikon D40) | HSV model | Color | Qualitative | - | [ |
| Alloy 600 | Tetrathionate solution | SCC | CCD camera | Binary | - | Quantitative | Acoustic Emission and Electrochemical Noise | [ |
Fig. 3. Corrosion extent of Q235B steel determined using fuzzy K-S entropy. Corrosion images of Q235B steel exposed for various times to a marine atmosphere in Zhoushan (three parallel specimens were collected): (a) 2 days, (b) 10 days, (c) 20 days, (d) 191 days. (e) Change in horizontal fuzzy K-S entropy over time (reprinted with permission from Ref. [163]).
Fig. 4. Field corrosion image of aluminum alloy exposed to an urban atmosphere: (a) image acquisition using a KH3000 digital video-microscope system (Hirox. Co. Ltd.), (b) typical corrosion morphology images of 7B04-T6 aluminum alloy samples exposed to an atmospheric environment for various times, (c) the selected region for discrete wavelet transform (DWT), (d) a one-scale DWT, (e) a two-scale DWT, (f) a three-scale DWT, (g) energy distribution in aluminum alloy samples after exposure for various times, where d = days and H, V, and D correspond to horizontal, vertical, and diagonal detailed sub-images, respectively, and E = energy value (reprinted with permission from Ref. [105]).
Fig. 5. In situ microscopy of AISI 1040 steel during polarization in 3.1 × 10-3 mol dm-3 H2S with NaCl in acetate buffer (pH = 4.5). Snapshots at E =36.3 mV (a), E =54.4 mV (b), E =72.7 mV (c), E =90.8 mV (d), E = 108.9 mV (e) and E = 180.6 mV (f). (g) Representation of the specific pixel region as a function of time during polarization experiments corresponding to the pearlitic grains using the HSI color model: hue (solid line), saturation (dashed line), and intensity (dotted line). All potentials were measured vs. an open circuit potential (reprinted with permission from Ref. [93]).
Fig. 6. Two schematic diagrams (a, b), each showing nine atmospheric corrosion images obtained at different exposure times. a1-a5 corroded areas have different gray values; b1-b5 corroded areas have the same gray values. (c) Energy value evolution of corrosion images corresponding to the two cases (reprinted with permission from Ref. [89]).
Fig. 7. In-situ corrosion viewed with a microscope: (a) initial corrosion stage without pits, (b) test area polarized at 300 mV (versus saturated calomel electrode), (c) gray level across the red line shown in (a) and (b) as a function of time during the pitting corrosion of 304 SS (reprinted with permission from Ref. [124]).
Fig. 8. Image processing to examine an organic coating, where (a) is the corrosion image of an epoxy iron red primer coating showing corrosion beneath the coating, (b) is the image in (a) after fuzzy enhancement and after binary imaging (c) [126]. Corrosion morphology of a polyurethane coating; (d) before exposure, (e) after exposure to a marine splash zone for 24 months, (f) exposed to a marine atmosphere for 24 months (reprinted with permission from Ref. [109]).
Fig. 9. Metallic materials corrosion image collection in the field using a portable CCD camera: (a) image collection, (b, c) corrosion images of 304 SS exposed to a marine atmosphere.
Fig. 10. Research opportunities to use various techniques and mathematical methods to predict and evaluate metallic materials corrosion.
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