Portable Lab for On-Site Metal Testing

Industrial & Engineering

Traditionally, testing metals for corrosion resistance or defects requires sending parts to specialized laboratories. This means components—like pipelines, welds, or machinery—must be dismantled and transported, which is costly, time-consuming, and often impractical. Existing devices are bulky and not suited for on-site use.

The Invention

This patent introduces a compact, mobile device that can perform electrochemical tests—especially the DL-EPR test—directly on metal parts in the field. The device uses three electrodes (measuring, counter, and reference), a small chamber filled with a test liquid, and a seal that attaches to the metal surface. The chamber ensures accurate measurements by keeping the test liquid in place and isolating it from air.

What’s New

The inventive step lies in making the entire testing process portable and autonomous. Instead of bringing the metal to the lab, the lab comes to the metal. The device can be clamped or magnetically attached to surfaces, filled with temperature-controlled test fluids from cartridges, and even purged with inert gas to prevent air contamination. It can also integrate sensors, cameras, and wireless data transfer, and in some designs, be mounted on wheeled or drone-like carriers to inspect pipelines automatically.

Benefits

  • On-site testing saves dismantling and transport costs.
  • Faster defect detection, even during production or immediately after welding.
  • Reliable results through temperature control, sealed chambers, and air purging.
  • Flexible use across many metals and test methods.
  • Automation reduces labor and increases safety, especially in hard-to-reach environments.

Broader Impact

This invention could transform industries like energy, construction, aerospace, and manufacturing by making regular, precise corrosion testing practical anywhere. It supports sustainability by extending equipment lifespans, preventing failures before they cause leaks or accidents, and reducing waste from unnecessary part replacements. In short, it brings laboratory-grade testing to the field, improving safety, efficiency, and environmental responsibility.

Disclaimer

The image and video are AI-generated based on the description of the invention in its patent application and are intended for illustrative purposes only.

It explains the concept and is not the actual product as it still needs to be developed.

Market Need

Corrosion is a massive global problem—causing failures in pipelines, aircraft, ships, bridges, and industrial plants. According to NACE International, the global cost of corrosion exceeds $2.5 trillion annually (about 3–4% of global GDP). A large portion of this cost arises from late detection of defects and reliance on costly laboratory testing. Industries urgently need faster, cheaper, and portable ways to test metals on-site.

This invention addresses that pain point directly: instead of dismantling equipment and sending it to labs, engineers can perform high-precision corrosion and defect analysis immediately on location.

Technical Feasibility

The device builds on well-established electrochemical testing methods (like DL-EPR) but makes them compact, mobile, and user-friendly. Key features such as sealed chambers, replaceable test-fluid cartridges, temperature control, and wireless data transfer make it technically feasible with today’s materials and electronics.

  • Sensors and automation are already common in portable devices.
  • Electrochemical test methods are proven accurate for corrosion analysis.
  • The novel combination of portability + automation + precision is the differentiator.

Challenges may include miniaturization of electrodes without losing accuracy, robust sealing in harsh environments, and ensuring safety with test fluids. All are solvable with current engineering practices.

Potential Applications

  • Oil & Gas Pipelines – On-site weld seam and pipeline integrity testing.
  • Aerospace & Aviation – Rapid corrosion checks on aircraft parts without grounding.
  • Construction & Infrastructure – Bridge and building steel reinforcement testing.
  • Energy (Nuclear, Renewable, Power Plants) – In-situ monitoring of critical metal structures.
  • Manufacturing & Shipbuilding – Quality assurance during and after production.

The addressable market is broad: essentially any industry dependent on metal reliability.

Market Size & Value

  • The non-destructive testing (NDT) market is projected to reach $24–26 billion by 2030 (CAGR ~6–7%).
  • The portable NDT equipment segment is already worth ~$3–5 billion and growing, driven by demand for mobility and faster inspections.
  • A specialized portable electrochemical analyzer could realistically target $500 million–$1 billion annually, given adoption across oil & gas, aerospace, construction, and energy sectors.

Uniqueness & Competitive Edge

Most existing devices are lab-bound or bulky, while portable testers today focus more on ultrasonic, radiographic, or magnetic methods, not high-precision electrochemical analysis.
This invention is unique in combining:

  • True mobility (clamps, suction, or drone-based deployment).
  • Precision electrochemical methods (DL-EPR and more).
  • Automated data collection and wireless reporting.
    This positions it as a niche but high-value disruptor in the NDT market.

Conclusion: Commercial Viability

The invention is commercially promising, with strong demand in industries where corrosion failures are catastrophic and costly. It sits at the intersection of a $25B NDT market and a $2.5T global corrosion problem. Technical hurdles are manageable, applications are broad, and the uniqueness lies in enabling lab-grade electrochemical testing in the field.

Overall, this is a high-potential innovation with realistic commercial pathways—initially in oil & gas and aerospace (high-value, safety-critical industries), then scaling into construction and manufacturing.