In-Situ Replication Metallography and Replica Testing

As one of the largest independent providers of non-destructive testing (NDT) services, Element offers unrivaled experience and expertise in in-situ replication metallography to perform and analyze replica tests for obtaining microstructures on-site, for subsequent examination and evaluation in our fully accredited laboratories.

Replica testing procedures and techniques 

1. Selection of location
2. Visual inspection
3. Surface and specimen preparation (metallographic grinding, polishing and etching)
4. Microstructure examination
5. Replication
6. Examination of replica

In-situ replication metallography and replica examination services 

• Microstructure evaluation 

• Creep damage assessment – mostly on high-pressure and high-temperature equipment such as steamlines, boilers and reactors. 

• Thermal degradation of the materials – mostly on stainless steels in high-temperature equipment, where detrimental precipitation and the Degree of Sensitization (DOS) can be assessed. Thermal degradation can also occur during unwanted high-temperature exposure, such as fire damage or hot spots. 

• Failure analysis/crack analysis 

• Hydrogen Embrittlement (HE)  

• Stress Corrosion Cracking (SCC)  

• Intergranular Corrosion (IGC)  

• Graphitization

We specialize in testing high-pressure and high-temperature equipment across petrochemical, refinery, and oil & gas industries. Our expertise covers a wide range of metals and alloys, including austenitic stainless steels, nickel and chromium based alloys, carbon steel, low alloy steel, and duplex stainless steel. We focus particularly on critical components like steamlines, boilers, and reactors where material integrity is paramount.

Our metallurgists are highly skilled in the preparation of the replicas using a number of techniques and can advise you in choosing the appropriate method for your specific project needs.

From on-site evaluation of a component’s metallurgical and heat treatment condition to conducting a remaining life assessment study and a failure analysis project, our skilled teams of metallurgists can verify the on-site, non-destructive microstructure of any given component.

Combine your testing  

Our experts combine tests to get the most complete indication of the examined equipment; for instance, to determine whether a material has been thermally degraded, the replica tests are combined with hardness measurements. If microstructure examination is not sufficient on the surface alone, our metallurgists can take boat samples for examinations on (partial) cross-sections. 

Our  team operates from energy testing hubs across the world, providing global access to our expert capabilities. Find out where your nearest energy testing hub is on our Locations Page.