An in-situ corrosion sensor has been developed that allows early detection of coating degradation and substrate corrosion. The sensor is based on electrochemical impedance spectroscopy (EIS) and extends the use of this established laboratory technique to ambient environments and field applications. The sensor directly detects degradation of the structure or specimen of interest, as opposed to degradation of a sensor component. It has applicability both to field inspection and
condition-based maintenance and to coating screening and development. A permanent, painted version is suited for inaccessible areas of structures or areas/specimens for which one wishes to take repeated measurements over time, such as a panel in an accelerated test chamber or a hidden area of an aircraft. A hand-held version is suited for spot inspection or if a permanent sensor is not desired for ascetics, aerodynamics, or other reasons. Both sensors utilize commercial potentiostats for data acquisition and analysis. The sensors are able to detect and quantify moisture absorption by a coating and the early stages of degradation well before any visual indication of deterioration. The sensor measurements have been shown to predict the amount of corrosion at the end of accelerated tests that have been correlated with service performance. They have also been used to evaluate coating systems and inspect structures in the field.