Corrosion and Its Prevention (5 days)
 

Course Overview                                                                                   (Online Registration)

This comprehensive corrosion course consists of 10 half-day modules covering virtually every aspect of corrosion. The course is structured in a flexible modular format so that beginners will establish a strong foothold from the basic modules dealing with the necessary concepts and principles before taking advanced topics, while advanced participants will be able to choose specific modules of their interest. The smooth integration of the 10 half-day modules provide an excellent avenue for corrosion practitioners, designers, technical managers, inspection and maintenance engineers, 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, prevention, testing and monitoring.

Any module or any combination of modules is available for in-house training, online and distance learning worldwide. Modules can be customized to meet the specific needs of your organization.

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• Module 1 Enabling Theory for Aqueous Corrosion

• Module 2 Principles of Aqueous Corrosion

• Module 3 Oxidation and High Temperature Corrosion

• Module 4 Different Forms of Corrosion: Mechanisms, Recognition & Prevention

• Module 5 Corrosion in Specific Environments

• Module 6 Design and Materials Selection for Corrosion Prevention

• Module 7 Corrosion Protection by Coatings

• Module 8 Corrosion Inhibitors and Other Methods of Conditioning the Environment

• Module 9 Cathodic Protection and Anodic Protection

• Module 10 Corrosion Testing and Monitoring

1.1 Introduction

     1.1.1 Definition of corrosion
     1.1.2 Types of corrosion
     1.1.3 The cost of corrosion
     1.1.4 Significance of corrosion control
 
1.2 Electrical concepts relevant to corrosion

     1.2.1 Resistivity, conductivity, impedance
     1.2.2 Electron conductor, electrolytic (ionic) conductor and semiconductor
     1.2.3 Direction of current and flow of electrons

1.3 Matters of Substance

     1.3.1 Metals in the melting pot
     1.3.2 Defects in metals

1.4 Chemical and electrochemical concepts relevant to corrosion

     1.4.1 Ionization of water
     1.4.2 Definition of pH
     1.4.3 Ionization of metal in water
     1.4.4 Electrode process
     1.4.5 Anodic and cathodic reactions
     1.4.6 Passivation behavior of iron in nitric acid
     1.4.7 Standard redox potential
     1.4.8 EMF series
     1.4.9 Common reference electrodes
     1.4.10 The Daniel cell and Galvanic cell
     1.4.11 Galvanic series
     1.4.12 Essential components in a corrosion cell
     1.4.13 Common types of corrosion cells in practical situations
     1.4.14 General methods of corrosion control

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2.1 Why does a metal corrode?
      - Thermodynamic aspects of aqueous corrosion

      2.1.1 Stable states of metals in nature
      2.1.2 The driving force for corrosion
      2.1.3 The energy change and the cell potential: Faraday's Law
      2.1.4 Effect of concentration: the Nernst Equation
      2.1.5 Effect of pH: the potential-pH diagram (Pourbaix diagram)
      2.1.6 Practical applications of E-pH diagram and its limitations

2.2 How does a metal corrode? - Kinetics of corrosion

      2.2.1 Rate of reaction and rate constant
      2.2.2 Factors affect rate of reaction
      2.2.3 Anodic and cathodic current densities
      2.2.4 Exchange current density
      2.2.5 The mixed potential theory
      2.2.6 E-log(i) Evans diagram
      2.2.7 Tafel Equation and Tafel plot for corrosion rate determination
      2.2.8 Linear polarization and Stern-Geary Equation
      2.2.9 Type of polarization and rate-controlling step
      2.2.10 Concentration polarization and the importance of dissolved oxygen
      2.2.11 Effect of oxidizer concentration on corrosion rate
      2.2.12 Effect of velocity on corrosion rate

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3.1 Oxidation of metals & alloys

      3.1.1 Mechanisms of ionic movements in metallic oxides
      3.1.2 Rate of oxidation and rate laws
      3.1.3 Effects of alloying elements on the protective property of oxides

3.2 Oxidation resistance of low-alloy steel

      3.2.1 Factors governing oxidation behavior
      3.2.2 Oxidation of iron
      3.2.3 Alloying effects on oxidation of iron
      3.2.4 Stress effects
      3.2.5 Commercial low-alloy steels in air or oxygen

3.3 Nature of environments

      3.3.1 Air and oxygen
      3.3.2 Steam
      3.3.3 Sulphur-containing gases
      3.3.4 Molten salts
      3.3.5 Molten metals

3.4 High temperature corrosion of cast iron

3.5 Corrosion of high-alloy steels

3.6 Nickel and its alloys

      3.6.1 Oxidation
      3.6.2 Sulphidation
      3.6.3 Hot-salt corrosion
      3.6.4 Carburisation and attack by carbon-containing gases
      3.6.5 Corrosion by molten metals and salts

3.7 Corrosion of advanced ceramics

3.8 Materials for high temperature applications

3.9 Current development and future trend

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4.1 Uniform corrosion
4.2 Galvanic corrosion
4.3 Dealloying and Graphitisation
4.4 Crevice corrosion
4.5 Pitting corrosion
4.6 Intergranular stress corrosion cracking, weld decay and knife-line attack
4.7 Exfoliation
4.8 Filiform corrosion
4.9 Microbiologically-Influenced Corrosion (MIC)
4.10  Environment-sensitive cracking
         4.10.1 Stress corrosion cracking (SCC)
         4.10.2 Hydrogen-induced cracking (HIC)
         4.10.3 Sulfide stress cracking (SSC)
         4.10.4 Caustic embrittlement
         4.10.5 Liquid metal embrittlement (LME)

4.11 Hydrogen Damage
        4.11.1 Cold hydrogen attack or hydrogen blistering
        4.11.2 Hot hydrogen attack or decarburization (methane gas embrittlement)
        4.11.3 Hydride (MHx) embrittlement
        4.11.4 Hydrogen Induced Cracking (HIC),
        4.11.5 Stress Oriented Hydrogen Induced Cracking (SOHIC)
        4.11.6 Sulfide Stress Corrosion Cracking (SSC)

4.11 Corrosion fatigue
4.13 Fretting
4.14 Erosion corrosion, impingement attack and cavitation damage
4.15 Stray current corrosion

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5.1 Corrosion in atmospheres

      5.1.1 Type of atmospheres and classification of corrosiveness
      5.1.2 Importance of relative humidity on rate of corrosion
      5.1.3 Other major factors affect the rate of corrosion
      5.1.4 Common forms of corrosion encountered in atmospheres
      5.1.5 Corrosion behavior of common engineering materials
               under atmospheric condition
      5.1.6 Control and prevention methods

5.2 Corrosion in potable water, natural waters
      and seawater systems

      5.2.1 Compositions of waters
      5.2.2 Effect of pH
      5.2.3 Corrosion resistance of common metals and alloys in water systems
      5.2.4 Corrosion control and prevention methods

5.3 Corrosion in Soils

      5.3.1 Characterisation of the soil environment
      5.3.2 Soil resistivity and rate of corrosion
      5.3.3 Other factors affect the form and rate of corrosion
      5.3.4 Corrosion resistance of common metals and alloys in soil
      5.3.5 Corrosion control and prevention methods

5.4 Corrosion in Concrete Structures

      5.4.1 Characteristics of the concrete environment
      5.4.2 Mechanisms of reinforcement corrosion
      5.4.3 Control and prevention methods
      5.4.4 Current development and future trend

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6.1 Design guidelines for corrosion prevention

      6.1.1 General classification of materials
      6.1.2 General classification of environment
      6.1.3 The natural matching of a material with an environment
      6.1.4 Good design practice for corrosion prevention
      6.1.5 Case studies: the Good, the Bad and the Ugly

6.2 Corrosion resistance properties of stainless steels and
      super duplex stainless steels

      6.2.1 Composition and classification of stainless steels
      6.2.2 Properties of stainless steels and super duplex stainless steels
      6.2.3 Effect of alloying elements on the corrosion resistance
      6.2.4 Composition and structure of passive films on stainless and duplex steels
      6.2.5 Precipitation of intermetallics: sigma, chi and Laves phases, delta ferrite, alpha prime phase
              and 475°C embrittlement
      6.2.6 Effects of potential, pH, alloy composition on the stability of passive films
      6.2.7 Resistance to uniform, localized corrosion and stress corrosion cracking
      6.2.8 Common engineering applications of stainless and duplex steels

6.3 Corrosion resistance of other common engineering materials

      6.3.1 Cast iron, carbon steels and low alloys steels
      6.3.2 Nickel and nickel alloys
      6.3.3 Aluminum and aluminum alloys
      6.3.4 Copper and copper alloys
      6.3.5 Titanium and titanium alloys
      6.3.6 Zinc, tin and their alloys

6.4 Corrosion resistance of non-metallic materials

      6.4.1 Plastics, rubber, elastomers and vitreous materials
      6.4.2 Composite materials
      6.4.3 Ceramic materials

6.5 Current development and future trend

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7.1 Metallic coatings

      7.1.1 Desired properties of metallic coatings
      7.1.2 Type and classification of metallic coatings
      7.1.3 Protection mechanisms
      7.1.4 Electroplating and electroless plating
      7.1.5 Anodizing, phosphating and chromating
      7.1.6 Hot-dip galvanizing
      7.1.7 Thermal spray metallization
      7.1.8 Service life prediction

7.2 Organic coatings: - Paints

      7.2.1 Desired properties of organic coatings
      7.2.2 Formulation and classification of paints
      7.2.3 Protection mechanisms
      7.2.4 Surface preparation standards
      7.2.5 Methods of application
      7.2.6 Corrosion resistance of common paints
      7.2.7 Galvanizing vs zinc rich paints
      7.2.8 Coatings defects and failure analysis
      7.2.9 Service life prediction

7.3 Composite coatings

      7.3.1 Formulation and classification of composite coatings
      7.3.2 Methods of application
      7.3.3 Corrosion resistance properties

7.4 Combined use of organic coatings and cathodic protection

      7.4.1 Benefits of the combined systems
      7.4.2 Regulatory requirements
      7.4.3 Cost analysis
      7.4.4 Common applications

7.5 Current development and future trend

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8.1 Type, classification and inhibiting mechanisms

      8.1.1 Anodic inhibitor
      8.1.2 Cathodic inhibitor
      8.1.3 Mixed inhibitor

8.2 Formulation of common corrosion inhibitors

8.3 Applications and limitations

      8.3.1 Corrosion inhibitor in automotive systems
      8.3.2 Inhibitors for cooling water
      8.3.3 Inhibitors for potable water system
      8.3.4 Corrosion inhibitors for refineries and petrochemical plants

8.4 Volatile corrosion inhibitors (VCI)

      8.4.1 Mechanism of protection
      8.4.2 Formulation of common VCIs
      8.4.3 Applications and limitations
      8.4.4 Innovative products based on VCI

8.5 Film-forming rust-proof materials

      8.5.1 Type and classification
      8.5.2 Applications and limitations

8.6 Control of relative humidity

      8.6.1 Critical relative humidity
      8.6.2 Effect of atmospheric pollutants

8.7 Deaeration

      8.7.1 Solubility of oxygen in liquids
      8.7.2 Effect of oxygen content on rate of corrosion
      8.7.3 Effect of pH
      8.7.4 Effect of temperature
      8.7.5 Low pressure and high pressure boiler systems

8.8 Current development and future trend

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9.1 Cathodic Protection: Theory, Practice and Applications

      9.1.1 How it works and why it works
      9.1.2 Criteria of protection
      9.1.3 Sacrificial anode cathodic protection system
      9.1.4 Properties of anode materials and selection
      9.1.5 Applications of sacrificial anode cathodic protection
      9.1.6 Innovative products based on sacrificial anode system
      9.1.7 Impressed current cathodic protection system (ICCP)
      9.1.8 Properties of anode materials and selection
      9.1.9 Instruments for cathodic protection
      9.1.10 Cathodic protection in sea water
      9.1.11 Cathodic protection in soil
      9.1.12 Cathodic protection in concrete structures

9.2 Anodic Protection: Theory, Practice and Application

      9.2.1 Theory of anodic protection
      9.2.2 System requirements
      9.2.3 Criteria of protection
      9.2.4 Practical applications

9.3 Cathodic or Anodic, which protection method to use?

      9.3.1 Applicable materials
      9.3.2 Applicable environments
      9.3.3 Effectiveness of protection

9.4 Current development and future trend

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10.1 Type and classification of corrosion testing

10.2 The nature of corrosion process

10.3 Conventional methods

        10.3.1 Weight loss coupon method
        10.3.2 Electrical resistance method

10.4 Electrochemical methods

        10.4.1 Linear polarization resistance for determining corrosion rate
        10.4.2 Potentiodynamic polarization for corrosion behavior analysis
        10.4.3 Potentiostatic polarization for surface stability analysis
        10.4.4 Electrochemical potentiokinetic reactivation test for susceptibility to
                   intergranular stress corrosion cracking or weld decay
        10.4.5 Cyclic polarization test for pitting resistance
        10.4.6 AC impedance test for corrosion rate measurements and coatings evaluation
        10.4.7 Zero resistance ammetry (ZRA) test for galvanic corrosion (weld test)
        10.4.8 Electrochemical noise for monitoring localized corrosion

10.5 Principal online corrosion monitoring techniques

        10.5.1 System components and installation strategy
        10.5.2 Applications and limitations

10.6 Other methods of corrosion testing and monitoring

       10.6.1 Radiographics, ultrasonic and electromagnetic methods
       10.6.2 Monitoring water chemistry and corrosion products
       10.6.3 Cathodic protection monitoring

10.7 Current development and future trend

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All corrosion courses can be conducted at any time for you as in-house training courses or distance-learning courses. There is no minimum or maximum number of participants required for each course. Public corrosion short courses, seminars and workshops are also conducted regularly. If you are concerned with corrosion in your business, in-house training is a great solution to train a group of employees from Production, Quality Assurance, Inspection & Maintenance, and Technical Sales & Support on corrosion control & corrosion prevention technology. Contents of all corrosion courses can be customized to fit your organization's needs. Requests for in-house training courses, online courses & distance learning courses from overseas countries are also welcome. Click here for course registration online.
 

All corrosion courses can be conducted through online or distance learning. A master hard copy of corrosion course notes can be mailed to your organization or a password may be issued to course participants for accessing the online course materials. Instructions, course assignments, discussions and questions related to the corrosion courses can then be posted to the website or exchanged through email for a period up to 12 months. Click here for course registration online.

If you are involved in teaching corrosion courses, you may wish to purchase a complete set of the PowerPoint slides and the computerized test banks (in MicroTest format) with solutions. These presentations are suitable for teaching corrosion courses at different levels (from undergraduate to postgraduate) and durations (from 6 hrs to 40 hrs). The PowerPoint slides can be easily edited and customized to your own styles. The test bank contains over 1,000 questions for your use in tutorials, quizzes, tests or examinations. These questions are conveniently grouped into 4 categories in the test bank: (1) true or false, (2) multiple choice, (3) calculation, and (4) reasoning & open-ended discussions).  If you need more information, please contact Corrosion Clinic.

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