Corrosion Short Course: Corrosion, Metallurgy, Failure Analysis and Prevention, presented by NACE certified Corrosion Specialist , WebCorr Corrosion Consulting Services.

Corrosion, Metallurgy, Failure Analysis and Prevention

Course Overview

This 5-day 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 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.

Course Outline

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

    3.4 Why is weldment particularly susceptible to microbiologically influenced corrosion?
    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 Corrosion under insulation
     3.7 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

4.7 Software Solutions to Industrial Corrosion: Overview of Corrosion Modeling and Corrosion Prediction Software

ABC-Compass: Ammonium Bisulfide Corrosion Modeling and Life Prediction

ACE - Apps for Corrosion Engineers: A Collection of Essential Corrosion Software Applications for Corrosion Engineers, Corrosion Researchers, and Corrosion Technicians in Laboratories and in Fields

ACMF-Compass: Modeling and Prediction of the Effects of AC and Magnetic Field on Metal Corrosion

Atmosphere-Compass: Prediction and Modeling of Atmospheric Corrosion of Metals and Alloys

CCC-Compass: Modeling and Prediction of Caustic Corrosion and Caustic Stress Corrosion Cracking

CIPAL-Compass: Copper-Induced Pitting in Aluminium Alloys - Modeling, Life Prediction and Process Control

CO2Compass: Modeling and Prediction of Corrosion by Carbon Dioxide (CO2), Hydrogen Sulfide (H2S), Acetic Acid (HAc), Elemental Sulfur (S), and Mercury (Hg) in Oil and Gas Pipelines and Production Tubing

Concrete-Compass: Concrete Corrosion Prediction and Modeling

CP-Compass-Pipeline: Cathodic Protection Design Calculations, Verification, Assessment and Solution for Underground Pipelines

CP-Compass-Concrete: Design Calculations for Cathodic Protection of Reinforced Concrete Structures

CRA-Compass: Corrosion Modeling and Corrosion Prediction for Corrosion Resistant Alloys - the Threshold Temperature and Chloride Concentration for Pitting, Crevice Corrosion, and Stress Corrosion Cracking (SCC)

CSR-Compass: Modeling and Remaining Life Prediction of Creep and Stress Rupture of Boiler and Heater Tubes

CUI-Compass: Prediction and Risk Assessment of Corrosion Under Insulation and Fireproofing

Dew-Point-Compass: Prediction of Dew Point Temperatures of Flue Gases and the Risk of Dew Point Corrosion

DWD-Compass: Modeling and Life Prediction of Corrosion in Drinking Water Distribution Systems

EVS-Compass: Extreme Value Statistics in Corrosion Modeling and Corrosion Life Prediction of Structures and Plant Assets

FAC-Compass: Erosion Corrosion and Flow - Accelerated Corrosion Modeling, Life Prediction and Materials Selection in Water-Steam Systems

FuelAsh-Compass: Fuel Ash Corrosion Modeling and Life Prediction of Boiler and Heater Tubes

GC-Compass: Galvanic Corrosion Prediction and Materials Compatibility Assessment

H2Compass: Modeling and Prediction of Low Temperature Hydrogen Damages (Hydrogen Blistering, Hydrogen-Induced Cracking, Hydrogen Embrittlement) and High Temperature Hydrogen Attack (HTHA)

H2SO4-Compass: Corrosion Prediction and Materials Selection Guide for H2SO4 Services

HCl-Compass: Corrosion Prediction and Materials Selection Guide for HCl Services

ISO15156-Compass: Modeling and Prediction of in-situ pH, Region of Environmental Severity, and Susceptibility to Sulfide Stress Cracking (SSC) of Carbon and Low Alloy Steels

NAC-Compass: Modeling and Prediction of High Temperature Naphthenic Acid Corrosion

O2Compass: Modeling and Prediction of High Temperature Oxidation

OCTG-Compass: Corrosion Prediction and CRA Materials Selection Guide for Oil and Gas Production Systems

PipelineCompass: Pipeline Corrosion Modeling, Prediction, Assessment and Solutions

PCW-Compass: Corrosion Prediction and Modeling in Process Cooling Water Systems

SC-Compass: Stray Current Corrosion and AC Corrosion - Identification, Assessment and Prediction

S-Compass: Modeling and Prediction of High Temperature Sulfidation/Sulfidic Corrosion/H2-H2S Corrosion and Low Temperature Elemental Sulfur Corrosion

Seawater-Compass: Seawater Corrosion Prediction for Metals and Alloys

Shipwreck-Compass: Shipwreck Corrosion Modeling and Corrosion Prediction

Soil-Compass: Soil Corrosion Prediction and Modeling for Metals and Alloys

VPC-Compass: Prediction and Modeling of Internal Corrosion in Vapor Phase in Closed Systems

VPC-Compass-SE: Prediction and Modeling of Corrosion in Microelectronic Packages

Who Should Attend This Corrosion Course

This 5-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.

Successful completion of this corrosion course helps participants prepare for their NACE certification examinations at the Corrosion Technician, Corrosion Technologist and Senior Corrosion Technologist levels.

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 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.

Click here to contact us for a quotation.

Online 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 3 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 or training, you may wish to purchase a complete set of the trainer's package for this training course. The trainer's package comes complete with ready-to-use PowerPoint slides (fully editable) and test bank (with answer keys). These ready-to-use PowerPoint slides contain high quality color photographs, illustrations, animations, audio and video clips. The test bank contains questions in four categories: (1) true or false, (2) multiple choice, (3) calculation, and (4) reasoning and open-ended discussions. The trainer's package is suitable for in-house training and university teaching. This is exactly the same package that WebCorr uses to deliver our current training course.

The one-time lump sum fee allows your organization to use the training package and also modify it. For example, your organization may modify the course contents and re-name/re-brand the course under your organization’s name. WebCorr only retains the copyright of the original PowerPoint slides and test bank.

Click here to contact us if you need more information on the trainer's package.

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