In Situ Raman Spectroscopy for Early Corrosion Detection in Coated AA2024-T3

Here we describe the synthesis and evaluation of a molecular corrosion sensor that can be applied in situ in aerospace coatings, then used to detect corrosion after the coating has been applied. A pH-sensitive molecule, 4-mercaptopyridin (4-MP), is attached to a gold nanoparticle to allow surface-enhanced Raman-scattering (SERS) for signal amplification. These SERS nanoparticles, when combined with an appropriate micron-sized carrier system, are incorporated directly into an MIL-SPEC coating and used to monitor the process onset and progression of corrosion using pH changes occurring at the metal–coating interface. The sensor can track corrosion spatially as it proceeds underneath the coating, due to the mobility of the proton front generated during corrosion and the homogeneous distribution of the sensor in the coating layer. To our knowledge, this report is the first time a 4-MP functionalized gold nanoparticle has been used, along with SERS spectroscopy, to monitor corrosion in an applied commercial coating in a fast, non-contact way.