Corrosion, Metallurgy, Failure Analysis
and Prevention (3 days)

Course Overview                                                              (Online Registration)

This corrosion short 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. This 3-day course provides an excellent avenue for corrosion practitioners, failure analysis personnel, designers, technical managers, inspection and maintenance engineers, coatings and weld inspectors, quality control personnel and anyone who is interested in corrosion, metallurgy and materials failure analysis and its prevention. 

This corrosion short course can be taken as in-house training course, online course and distance learning course worldwide. It can also be customized to meet the specific needs of your organization.

Download course brochure in PDF

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   Intergranular corrosion and weld decay
        2.6.7   Exfoliation
        2.6.8   Filiform corrosion 
        2.6.9   Microbiologically-influenced corrosion (MIC) 
        2.6.10 Environment-sensitive cracking 
        2.6.11 Hydrogen damages
        2.6.12 Corrosion fatigue 
        2.6.13 Fretting 
        2.6.14 Erosion corrosion, impingement attack and cavitation damage 
        2.6.15 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: 
                 submicroscopic 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

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 are 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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