Basic Corrosion
5-Day Classroom Course
Description
The Basic Corrosion Course focuses on corrosion and the potential problems caused by corrosion. It provides a basic but thorough review of causes of corrosion and the methods by which it can be identified, monitored, and controlled. Active participation is encouraged through hands-on experiments and case studies, as well as an open discussion format.
Who Should Attend
Anyone who needs to be able to recognize corrosion and understand its devastating potential, especially as it relates to his or her area of responsibility. This includes:
- Engineers
- Technicians
- Managers
- Supervisors
- Salespersons
- Inspector
- Anyone needing a basic understanding of corrosion
Prerequisites
No previous training in corrosion control is required. However, to gain the most from this course, a basic understanding of science and chemistry is recommended.
Course Highlights (include but are not limited to)
- Basics of Electrochemistry
- Types of Environments
- Engineering Materials
- Forms of Corrosion
- Corrosion Control & Prevention Methods
- Testing & Monitoring Techniques
Course Outline
I. Introduction
Definition of Corrosion
Basic Forms of Corrosion
Examples of Corrosion
Significance of Corrosion
Costs of Corrosion
Corrosion-related Costs
Indirect Consequences of Corrosion
II. Electrochemistry
Basics of Electrochemistry
Corrosion Occurs Through Electrochemical Reactions
Oxidation/Reduction Reactions
Corrosion as an Electrochemical Process
Corrosion Requires a Complete Circuit
Thermodynamics
Potential
Reference Electrodes
The Galvanic Series
Nernst Equation
Pourbaix Diagrams
Kinetics
Faraday's Law
E-Log I Curves (Evans Diagrams)
Area Effects
Galvanic Corrosion
Concentration Cell Corrosion
Active/Passive Cells
Thermogalvanic Corrosion
Passivity
III. Environments
Introduction
Atmospheric
Underground
Physical Soil Characteristics
Chemical Soil Characteristics
Moisture Content
Electrical Resistivity
Aeration
Bacteria
Liquid
High Temperature
High-Temperature Oxidation
High-Temperature Reduction
IV. Engineering Materials
Introduction
Metals
Metallurgy Concepts
Carbon and Low-Alloy Steels
Cast Iron
Copper Alloys
Stainless Steels
Nickel-Based Alloys
Aluminum and Aluminum Alloys
Titanium
Nonmetals
Concrete
Plastics
Composite Materials
Elastomers
Ceramic Materials
V. Forms Of Corrosion
Introduction
Forms of Corrosion
Combination of Forms
General Attack Corrosion
Definition
Description
Recognition
Mechanism
Corrosion Rates
Predictability/Measurement
General Attack Corrosion - Performance of Metals and Alloys
Control of General Attack Corrosion
Localized Corrosion
Introduction
Types
Pitting
Definition
Mechanism
Pitting
Predictability/Measurement
Pitting Corrosion - Performance of Metals and Alloys
Control of Pitting Corrosion
Crevice Corrosion
Definition
Mechanism
Types
Crevice Corrosion - Performance of Metals and Alloys
Control of Crevice Corrosion
Filiform Corrosion
Definition
Mechanism
Filiform Corrosion - Performance of Metals and Alloys
Control of Filiform Corrosion
Galvanic Corrosion
Introduction
Definition
Mechanism
Electrochemical Process
Galvanic Series
Galvanic Corrosion Rates
Potential Difference
Nature of Environment
Polarization
Spatial Effects: Area, Distance, and Geometric Effects
Predicting Galvanic Attack
Galvanic Attack - Performance of Metals and Alloys
Control of Galvanic Attack
Environmental Cracking
Introduction
Definition
Mechanism
Recognition of Environmental Cracking
Controlling Cracking Factors
Types of Environmental Cracking
Stress Corrosion Cracking (SCC)
Definition
Recognition
Mechanism
SCC: Performance of Metals and Alloys
Hydrogen-Induced Cracking (HIC) and Sulfide Stress Cracking
Description
Recognition
Mechanism
Sulfide Stress Cracking (SSC)
NACE MR0175, "Sulfide Stress Corrosion Cracking Resistant
Material for Oil Field Equipment"
HIC - Performance of Metals and Alloys
Liquid Metal Embrittlement (LME)
Definition
Recognition
Mechanism
LME - Performance of Metals and Alloys
Corrosion Fatigue
Definition
Description
Mechanism
Corrosion Fatigue - Performance of Metals and Alloys
Control of Environmental Cracking
Design
Materials Selection
Modification of Environment
Electrochemical Techniques
Protective Coatings
Reduction in Residual Surface Stress
Flow Assisted Corrosion
Introduction
Definition
Types
Erosion-Corrosion
Description
Recognition
Mechanism
Erosion-Corrosion - Performance of Metals and Alloys
Impingement
Description
Recognition
Mechanism
Impingement-Performance of Metals and Alloys
Cavitation
Description
Recognition
Mechanism
Cavitation Corrosion - Performance of Metals and Alloys
Control of Velocity Effect Corrosion
Design
Materials Selection
Modification of Environment
Protective Coatings
Cathodic Protection
Intergranular Corrosion
Definition
Description
Recognition
Mechanism
Intergranular Corrosion- Performance of Materials
Intergranular Corrosion of Stainless Steel
General Sensitization
Weld Decay
Knife Line Attack
Aluminum and Aluminum Alloys
Copper and Copper Alloys
Nickel and Nickel-Based Alloys
Control of Intergranular Corrosion
Materials Selection
Design/Fabrication
Modification of Environment
Use of Proper Welding Procedures
Heat Treatment
Dealloying
Definition
Description
Recognition
Mechanism
Dealloying - Performance of Metals and Alloys
Copper Alloys
Brasses
Bronzes
Cast Iron
Controls of Dealloying
Materials Selection
Control of Environment
Use of Protective Coatings
Electrochemical Techniques
Design
Fretting Corrosion
Definition
Description
Recognition
Mechanism
Fretting Corrosion-Performance of Metals and Alloys
Controls
Materials Selection
Design
Use of Lubricants
High-Temperature Corrosion
Introduction
Definition
Recognition
Mechanisms
Oxygen Reactions
Reaction Rates
Linear Behavior
Parabolic Behavior
Oxide Scale Characteristics
Internal Oxidation
Sulfidation
Carburization
Decarburization (Hydrogen Effects)
Halide Effects
Molten-phases Formation
High-Temperature Corrosion- Performance of Metals and Alloys
Carbon and Low-Alloy Steels
Alloy Additions
Stainless Steels
Nickel-Based Alloys
Refractory Metals
Control of High-Temperature Corrosion
Materials Selection
Design
Modification of the Environment
Protective Coatings
VI. Methods of Corrosion Control
Design
Process Parameters
Temperature
Nominal Operating Temperature
Maximum Operating/Upset Temperature
Minimum Operating Temperature3
Velocity
Flow Rates
Chemistry
Construction Parameters
Welding
Accommodating Other Corrosion Control Measures
Dissimilar Metals
Crevices
Corrosion Allowance/Operating Lifetime
Maintenance and Inspection
Materials Selection
Factors that Influence Materials Selection
Corrosion Resistance in the Environment
Availability of Design and Test Data
Mechanical Properties
Cost
Availability
Compatibility with Other System Components
Life Expectancy of Equipment
Reliability
Appearance
Comparison with Other Corrosion Control Methods
Candidate Materials
Metals
Metallurgy
Nonmetals
Modification of Environment
Corrosion Inhibitors
Types of Inhibitors
Cathodic Inhibitors
Ohmic Inhibitors
Organic Inhibitors
Precipitation Inhibitors
Vapor Phase Inhibitors
Applications of Inhibitors
Aqueous Liquid Systems
Nonaqueous Liquid Systems
Gaseous Environments
Inhibitor Application Techniques
Continuous Injection
Batch Treatment
Squeeze Treatment
Coatings
Safety Considerations With Inhibitors
Handling
Disposal
Heat Transfer
Water Treatment
Cathodic and Anodic Protection
Principles
How Cathodic Protection Works
Galvanic Systems
Impressed-Current Systems
Impressed Current System Anodes
Impressed-Current Cathodic Protection System
Power Sources
Rectifiers
Solar Cells
Measurement of Cathodic Protection Effectiveness
Structure-to-Environment Potential
Test Coupons
Potential Change
Design
Regulatory requirements
Economics
Metal to be protected
Life requirements
Total current requirements
Variation in environment
Electrical shielding
Stray-current effects
Temperature
Wire and cable
Anode backfill
Protective coatings
Maintenance
Anodic Protection
Protective Coatings
Mechanisms of Protection
Barrier
Inhibitive Pigments
Cathodic Protection
Desirable Properties of a Coating
Chemical Resistance
Low-Moisture Permeability
Easy Application to Substrate
Adhesion to Substrate
Cohesive Strength
Tensile Strength
Flexibility/Elongation
Impact Resistance
Abrasion Resistance
Temperature Resistance
Resistance to Cold Flow
Dielectric Strength
Coating System Selection
Types of Exposure
Operating Conditions/Upset Conditions
Substrate
Ambient Conditions During Application
Environmental Regulations
Cost
Application of Coating During Operation or at Shutdown
Time Constraints
New Construction/Maintenance
Shop/Field Application
Design/Fabrication Considerations
Common Design Defects
Common Fabrication Defects
Surface Preparation
Coating Application
Manual
Spray
Production Techniques
Inspection
Surface Preparation Inspection
Wraps and Tapes
Insulation
Metallic Coatings
Coating Anodic to Base Metal
Coating Cathodic to Base Metal
VII. Corrosion Monitoring Techniques
Introduction
Inspection Methods
Visual
Radiographic (X-Ray)
Ultrasonic
Electromagnetic
Liquid Penetrant/Magnetic Particle Inspection
Specimen Exposure
Coupons
Special Coupons
Crevices
Stress
Galvanic Couples
Electrical Resistance
Electrochemical Methods
Linear Polarization Resistance
Electrochemical Impedance Spectroscopy
Electrochemical Noise
Water Chemistry
Deposits
Suspended Solids
Scale
Microbiological Fouling
Cathodic Protection Monitoring
Measurement Methods
Structure-to-Electrolyte Potentials
Criteria
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