Replica testing
Replica testing is one of MCI’s core areas of expertise, developed through 40+ years of experience with pressure and high-temperature installations worldwide.
Non-destructive materials analysis
How does replica testing work?
This non-destructive method enables us to assess the microstructure of materials without damaging the component itself. It is typically carried out on-site during a planned shutdown or in areas where high operating temperatures are not present.
Method:
Preparing the surface by grinding and polishing to approx. 1 micron
Etching the surface to reveal the microstructure
Applying a special film that precisely copies the microstructure (the replica)
Analysing the replica in our laboratory in Geleen, or via our mobile lab during plant shutdowns
Using replicas, we can not only analyse microstructures but also assess crack tips and support remaining life assessments.
Various replica techniques and additional methods, such as microhardness testing and PMI (Positive Material Identification) elemental analysis reinforce our conclusions.
Thanks to our high level of expertise, we obtain extremely accurate information that is crucial for strategic maintenance decisions, lifetime extension, and reliable repairs.
Integrated problem-solving: from inspection to solution
Leaks or failures in your installations? The OEM asks questions but provides no real answers.
Each party involved has its own interests, which often means a true solution never follows.
MCI offers an integrated approach, combining independent inspections, laboratory investigations, and practical solutions.
We work based on facts, not assumptions. Our goal: to ensure your installations remain reliable, safe, and fully operational.
