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Preferential Weld Corrosion: Causes and Prevention

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 Course Overview


Welding plays an essential role in the fabrication of components and structures such as reactor vessels, pipe work, heat exchangers etc. The associated local heating and cooling can significantly affect the corrosion resistance of the material. A welded joint constitutes a significant discontinuity in a structure from the compositional, metallurgical, and mechanical viewpoints. In many situations it is the performance of welded joints that determines the useful service life of the component or structure. This 3-day advanced course covers the causes of different forms of preferential weld corrosion and the practical methods of prevention. 


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


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 Course Outline


1. Introduction to Corrosion

2. Overview of Preferential Weld Corrosion

3. Weldment Metallurgy and Preferential Weld Corrosion
    3.1 Effect of Welding on 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 475C 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

    3.4 Why is weldment particularly susceptible to microbiologically influenced corrosion? 
    3.5 Preferential Weld 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 Preferential Weld Corrosion in CO2 and H2S Environments

4. Guidelines for the Prevention, Control, and Monitoring of Preferential Weld Corrosion

5. Case Studies

6. End-of-course examination


Course Outline |Who Should Attend |Registration |In-House |On-Demand |Online Courses |PPT Slides+Testbank |Course List

Who Should Attend This Corrosion Course


Corrosion practitioners, failure analysis personnel, designers, technical managers, inspection and maintenance engineers, reliability and integrity engineers, coatings and weld inspectors, quality control personnel.


 Registration for This Corrosion Course


Click here to register for this corrosion course online, or

Click here to download this corrosion course brochure with registration form in PDF format.


 In-House Training Corrosion Courses and On-Site Training Corrosion Course


If you are concerned with corrosion in your company, in-house training or on-site training is a great solution to train a group of employees from design, production, operation, quality assurance, inspection and maintenance, and technical sales and support on corrosion control and corrosion prevention technology. The contents of all our corrosion courses can be customized to fit your organization's needs.


There is no limit to the number of participants required for in-house training corrosion courses. We conduct the in-house training corrosion course at your company's premises worldwide, and at a time convenient to your company.


Click here to contact us for a quotation for in-house training corrosion courses.

 Corrosion Course-On-Demand


All our publicly scheduled corrosion short courses are conducted once a year. However, you do not need to wait for one year if you have missed any of the publicly scheduled corrosion courses as we have this unique corrosion course-on-demand scheme: we will conduct the course just for you (on an one-on-one basis) or for a small group from your company at a time and in a location convenient to you. This option costs significantly less than a full-scale in-house or on-site corrosion training program.


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 Online Corrosion Courses and Distance Learning Corrosion Courses


All our corrosion short courses are available for online or offline distance learning. You can start an online corrosion course at any time and learn at your own comfortable pace and schedule, whenever and wherever you are. You have around-the-clock access to the interactive and media-rich course materials, virtual labs, course instructions and course assessments. Discussions and questions related to the corrosion courses are posted on the website or exchanged through email for a period up to 12 months. Video conferencing or instant messaging can also be arranged for discussions of course topics. For those who do not have ready access to internet, we can send you our online course materials on a CD-ROM, or DVD, or USB flash drive for offline distance learning.


Click here to to register an online corrosion short course.


 PowerPoint Slides and Test Banks for Trainers, Instructors, Tutors, University Lecturers and Professors


If you are involved in teaching corrosion courses, you may wish to purchase a complete set of 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). These ready-to-use corrosion PowerPoint slides contain high quality color photographs, illustrations, animations and video clips. They can also be easily edited and customized to your own styles. The corrosion test banks contain over 1,000 corrosion questions for your use in tutorials, 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 and open-ended discussions).


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Course Outline |Who Should Attend |Registration |In-House |On-Demand |Online Courses |PPT Slides+Testbank |Course List

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