Detection of Intergranular Corrosion in Cold Plate Face Sheets

Cold plates are critical for cooling electronic systems in the shuttle. As a result of the environmental conditions in which they operate, water can condense between them and a support shelf. In some cases, this water results in intergranular corrosion in the face sheet. If the intergranular corrosion sufficiently penetrates the face sheet, a coolant leak could occur and jeopardize cold plate operation. This paper examines techniques for detecting and characterizing the intergranular corrosion, to enable recertification of cold plates that have been in operation for 15 plus years. Intergranular corrosion was artificially induced in the face sheets of a series of cold plate specimens using an electrochemical process. Some of the cold plate specimens were separated for destructive characterization of the extent of corrosion produced by the electrochemical process and to insure the induced corrosion was intergranular. The rest of the specimens were characterized nondestructively using several techniques. X-ray tomography and ultrasonic techniques provided the best indication of corrosion in these specimens and will be the focus of this paper. An x-ray tomography technique was shown to be the most effective technique for characterizing depth of the intergranular corrosion. From these measurements, corrosion profile maps were developed that were consistent with subsequent destructive evaluations of the specimens. This enabled the assessment of NDE (ondestructive evaluation) standards to evaluate the viability of other NDE techniques. Due to system constraints, a different technique must be used to inspect an entire cold plate. An ultrasonic technique was shown to be very reliable for detection of corrosion in the unbacked regions of the face sheet. The ultrasonic technique was performed in an alcohol bath to avoid additional corrosion during the NDE evaluation. A pulse echo technique that focuses on the RMS value of the signal is shown to be very sensitive to the presence of intergranular corrosion.