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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


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


If you are concerned with corrosion in your business, in-house 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 corrosion courses can be customized to fit your organization's needs.


There is no minimum or maximum number of participants required for in-house training corrosion courses. We conduct the in-house training corrosion course at your company's premises and at a time convenient to your company. Requests for in-house training corrosion courses from overseas countries are also welcome.


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 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 at a time and in a location convenient to you. This option costs significantly less than a full-scale in-house training program.


Click here to contact us for a quotation for taking this course as course-on-demand.


 Online and Distance Learning Corrosion Courses

All corrosion courses can be conducted through online or distance learning. An username and password will be emailed to course participants for accessing the online course materials. Alternatively, a CD-ROM containing the same online course material or a master hard copy of corrosion course notes can be sent to your organization. Instructions, course assignments, discussions and questions related to the corrosion courses are posted on the website. Free email support for online courses is provided for a period up to 12 months. A Certificate of Completion will be issued to participants who pass the online test with a score of 70% and above.


Click here to register this corrosion short course for online or distance learning.

 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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