Corrosion, Metallurgy, Failure Analysis & Prevention (3 days)
Course Objective
Created in July 1995 last updated April 2005
This course aims to provide the participants with an understanding of why and how corrosion occurs, the metallurgical and environmental factors influencing corrosion, and practical methods of corrosion control and failure prevention. Participants will be able to grasp the basic concepts related to corrosion, metallurgy and failure analysis, and to apply the state of the art technology in their workplace with an aim to achieve low cost reliability.
1. Basic Concepts in Corrosion
1.1 Introduction
1.2 Corrosion & Society
1.2.1 Corrosion: what it is
1.2.2 Corrosion: its economic,
social, political and environmental impacts
1.3 How to avoid liabilities due to corrosion
1.4 Lessons of history
1.5 Basic concepts relevant to corrosion
1.5.1 Terminology and convention
1.5.2 Primer in chemistry and
electrochemistry
1.5.3 Potential-pH diagram
1.5.4 Kinetics of corrosion
1.5.5 High temperature oxidation
2. Metallurgy and Corrosion
2.1 Introduction to Metallurgy
2.1.1 Extractive metallurgy
2.1.2 Mechanical metallurgy
2.1.3 Physical metallurgy
2.2 Metals in the melting pot
2.3 Defects in metals
2.3.1 Point defects
2.3.2 Line defects
2.3.3 Volume defects
2.4 The iron-carbon phase diagram
2.5 The microstructure of common metals/alloys
2.6 Different Forms of Corrosion: Mechanisms, Recognition &
Prevention
2.6.1 Uniform corrosion
2.6.2 Galvanic corrosion
2.6.3 Dealloying and Graphitisation
2.6.4 Crevice corrosion
2.6.5 Pitting corrosion
2.6.6 Filiform corrosion
2.6.7 Microbiologically-influenced
corrosion (MIC)
2.6.8 Environment-sensitive cracking
2.6.9 Corrosion fatigue
2.6.10 Fretting
2.6.11 Erosion corrosion, impingement
attack and cavitation damage
2.6.12 Stray current corrosion
3. Weldment Metallurgy and Corrosion
3.1 Weldment metallurgy and weldment corrosion
3.1.1 Factors affecting weldment
corrosion
3.1.2 Methods of welding
3.1.3 Welding austenitic SS vs carbon
steel
3.1.4 Residual stress and stress
concentration
3.1.5 Weld defects
3.1.6 Weld metallurgy
3.1.7 Weld metal composition
3.1.8 Iron contamination: its effects
& removal
3.1.9 Heat tint: its effects &
removal
3.1.10 Summary of fabrication defects
3.2 Precipitation of intermetallics (sigma, chi & Laves
phases) in stainless steels
3.2.1 Microstructural features in SS
3.2.2 Precipitation of delta ferrite
and Schaeffler Diagram
3.2.3 Alpha prime phase and 475°C
embrittlement
3.2.4 Precipitation of intermetallics:
sigma, chi and Laves phases
3.2.5 Chemical compositions of
various intermetallics and phases
3.2.6 Time-Temperature-Precipitation
diagrams for sigma, chi and Laves phases and carbides
3.2.7 Effect of chemical composition
on sigma precipitation
3.2.8 Effect of Nitrogen on sigma
precipitation
3.2.9 Effect of cold working on sigma
precipitation
3.2.10 Invisible (submicroscopic)
sigma/chi phases and their effects on corrosion
3.2.11 Time-temperature-precipitation
curves for various austenitic stainless
steels: precipitation of carbides, sigma, chi and Laves phases
3.3 Intergranular corrosion, weld decay and knifeline attack
3.3.1 Sensitization of austenitic
stainless steels
3.3.2 Cr profile along the grain
boundaries
3.3.3 Effect of carbon, molybdenum
and nitrogen on time-temperature- precipitation diagrams
3.3.4 Effect of cold working and
applied stress
3.3.5 Sensitization of Ferritic
Stainless Steels
3.3.6 Sensitization of Duplex
Stainless Steels
3.3.7 Effect sulfide inclusions in
stainless steels
3.3.8 Ferritic and duplex stainless
steels
3.3.9 Nickel-chromium alloys
3.3.10 Aluminum alloys
3.3.11 Weld decay and knifeline
attack on austenitic stainless steels
3.5 Weldment corrosion of various alloy systems
3.5.1 Austenitic stainless steels
3.5.2 Ferritic stainless steels
3.5.3 Nickel alloys
3.5.4 Duplex stainless steels
3.5.5 Carbon steels
3.5.6. Aluminum
3.6 CO2 and H2S Corrosion of various steels and alloys
3.7 Corrosion under insulation
3.8 Corrosion in seawater systems
3.9 Corrosion in atmosphere
4. Failure Analysis and Prevention
4.1 General approach to failure analysis
4.2 General methods of failure prevention
4.3 Corrosion Resistant Coatings
4.4 Cathodic & Anodic Protection
4.5 Corrosion Inhibitors
4.6 Corrosion Testing & Monitoring
WHO SHOULD ATTEND
This course provides an excellent avenue for corrosion
practitioners, designers, technical managers, maintenance engineers, inspection
and quality control personnel, and those involved in failure analysis to update
their appreciation of corrosion and the awareness of the emerging technologies
for corrosion control and failure prevention.