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Detection of Defect in Steel Sheets Under Coatings by Magnetic Flux Leakage

This project demonstrates the use of a portable magnetic flux leakage (MFL) setup built on STMicroelectronics’ SensorTile.box platform for detecting sub-coating defects in steel sheets. It shows how artificial gaps and different coatings affect flux leakage signals, validating the feasibility of low-cost embedded NDT.

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AI for Corrosion Prediction

This project focuses on building machine learning models to predict the corrosion performance of coated steel plates using data such as weight change, capacitance (electrochemical measurements), and adhesion strength. It establishes a framework to scale from simple lab experiments to predictive corrosion modeling.

Portable Field EIS Device for Coating Assessment

This project aims to translate the ASTM D8370-22 standard for Field Measurement of Electrochemical Impedance on Coatings and Linings into a portable diagnostic tool for quick, on-site coating evaluation.

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Detection of Wheel Misalignment Using Magnetic Sensors

This project explores a magnetic sensor–based technique for detecting wheel misalignment, focusing on toe and camber angles. Misalignment can affect vehicle performance, safety, and tire wear. Traditional alignment machines are bulky and expensive. This work demonstrates how a compact magnetometer setup can reliably measure misalignments.

publications

Design and Fabrication of a Simple and Inexpensive Measurement Probe for the Evaluation of Thermal Conductivity of Nanofluids

This work presents a low-cost transient hotwire probe for measuring thermal conductivity in nanofluids. The compact design emphasizes ease of fabrication, robustness, and flexibility in sample size, with accuracy validated on reference liquids and demonstrated on Fe3O4 ferrofluids and TiO2 nanofluids.

Recommended citation: Tamhane D, Anantharaman M.R. Design and Fabrication of a Simple and Inexpensive Measurement Probe for the Evaluation of Thermal Conductivity of Nanofluids. Journal of Nanofluids. 2017;6:390–394.
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On the Attenuation of Light by a Polydimethylsiloxane (PDMS) Foam and Its Implementation as a Weight Sensor

This paper reports how PDMS foam attenuates transmitted light under compression and demonstrates its use in a low-cost, repeatable weight sensor. The optical response follows an exponential fit akin to Lambert’s law, enabling precise sensing in the 500–2800 g range with no hysteresis.

Recommended citation: Tamhane D.U., Morarka A.R. On the Attenuation of Light by a Polydimethylsiloxane (PDMS) Foam and Its Implementation as a Weight Sensor. MAPAN. 2017;32:1–6.
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Non-invasive Detection of Extent of Corrosion in Steel Reinforcing Bars by Magnetic Force Measurement

Presents a strain-gauge–based magnetic force measurement technique for non-invasive detection of corrosion in steel rebars within RCC structures. Demonstrates insensitivity to PVC insulation and potential for in-situ structural health monitoring.

Recommended citation: Tamhane D., Banerjee S., Tallur S. Non-invasive Detection of Extent of Corrosion in Steel Reinforcing Bars by Magnetic Force Measurement. In: Mukhopadhyay C.K., Mulaveesala R. (eds) Advances in Non-destructive Evaluation. Lecture Notes in Mechanical Engineering. Springer, 2021.
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Smart Cathodic Protection System for Real-Time Quantitative Assessment of Corrosion of Sacrificial Anode Based on Electro-Mechanical Impedance (EMI)

This work introduces an EMI-based smart cathodic protection system that non-destructively quantifies early-stage corrosion of zinc sacrificial anodes. Analytical and experimental results show that resonance frequency shifts in PZT-anode assemblies provide a reliable metric for real-time anode degradation monitoring.

Recommended citation: Tamhane D., Thalapil J., Banerjee S., Tallur S. Smart Cathodic Protection System for Real-Time Quantitative Assessment of Corrosion of Sacrificial Anode Based on Electro-Mechanical Impedance (EMI). IEEE Access. 2021;9:12229–12240.
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Vibration-based inverse graphical technique for thickness estimation of bulk acoustic wave (BAW) resonators: application for corrosion monitoring of sacrificial anodes

This paper proposes a calibration-free graphical method to estimate zinc and zinc-oxide layer thicknesses on sacrificial anodes from bulk acoustic wave resonances. Validated with finite element analysis and accelerated corrosion experiments, the approach offers a simple and reliable tool for real-time anode health monitoring.

Recommended citation: Thalapil J, Tamhane D, Banerjee S, Tallur S. Vibration-based inverse graphical technique for thickness estimation of bulk acoustic wave (BAW) resonators: application for corrosion monitoring of sacrificial anodes. Smart Mater. Struct. 30 (2021) 055015.
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Corrosion Monitoring of Sacrificial Anodes Based on Contour Plot Analysis of Electro-Mechanical Impedance Spectra

Presents a calibration-free contour-plot (graphical) technique to extract zinc and zinc-oxide film thicknesses from resonance frequencies in EMI spectra. Validated with FEA and impressed-current corrosion experiments, the method is computationally light and suitable for in-situ anode health monitoring.

Recommended citation: Thalapil J., Tamhane D., Banerjee S., Tallur S. Corrosion Monitoring of Sacrificial Anodes Based on Contour Plot Analysis of Electro-Mechanical Impedance Spectra. Proc. Transducers 2021.
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Feature Engineering of Time-Domain Signals Based on Principal Component Analysis for Rebar Corrosion Assessment Using Pulse Eddy Current

This paper presents a pulsed eddy current probe with an AMR sensor for non-destructive rebar corrosion detection. By applying PCA to time-domain features, the system enhances sensitivity at large lift-offs and enables quantitative estimation of rebar diameter loss.

Recommended citation: Tamhane D., Patil J., Banerjee S., Tallur S. Feature Engineering of Time-Domain Signals Based on Principal Component Analysis for Rebar Corrosion Assessment Using Pulse Eddy Current. IEEE Sensors Journal. 2021;21(19):22086–22094. doi:10.1109/JSEN.2021.3103545.
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Monitoring Corrosion in Sacrificial Anodes With Pulsed Eddy Current and Electromechanical Impedance: A Comparative Analysis

A head-to-head comparison of pulsed eddy current (PEC) and electro-mechanical impedance (EMI) techniques for quantifying corrosion of zinc sacrificial anodes. Experiments and FEM show EMI is highly sensitive to incipient corrosion while PEC provides linear tracking over anode lifetime — suggesting a combined sensing strategy.

Recommended citation: Tamhane D., Banerjee S., Tallur S. Monitoring Corrosion in Sacrificial Anodes With Pulsed Eddy Current and Electromechanical Impedance: A Comparative Analysis. IEEE Sensors J. 2022;22(8):8147–8154. doi:10.1109/JSEN.2022.3157646.
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Performance evaluation of electro-mechanical impedance based state of health estimation of sacrificial anodes in reinforced concrete structures

This study demonstrates that electro-mechanical impedance (EMI) sensing with PZT transducers can sensitively track the state-of-health of sacrificial anodes embedded in concrete. The RMSD of conductance spectra offers a non-destructive, real-time metric for monitoring anode degradation.

Recommended citation: Tamhane D. Performance evaluation of electro-mechanical impedance based state of health estimation of sacrificial anodes in reinforced concrete structures. Constr Build Mater. 2022.
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Potentiostat-Independent Tools for Electrochemical Assessment of Performance of Coatings, Admixtures, and Corrosion Inhibitors

Introduces low-cost, field-deployable electrochemical tools—Inhibitor Performance Meter, Accelerated Corrosion Tester, and Dielectric Film Analyzer—that eliminate potentiostat dependency for evaluating coatings, admixtures, and corrosion inhibitors.

Recommended citation: Tamhane D. Potentiostat-Independent Tools for Electrochemical Assessment of Performance of Coatings, Admixtures, and Corrosion Inhibitors. Proc. CORCON 2025, Jaipur, India.
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