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A Modular Course on
CORROSION CONTROL & PREVENTION
Course Overview
This comprehensive course consists of 10 half-a-day modules covering almost every aspect of corrosion. The course is structured in a flexible modular format so that beginners will establish a strong foothold from the basic modules dealing with the necessary concepts and principles before taking advanced topics, while advanced participants will be able to choose specific modules of their interest. The smooth integration of the 10 half-a-day modules provide an excellent avenue for corrosion practitioners, designers, technical managers, maintenance engineers, quality control personnel and those involved in failure analysis to update their appreciation of corrosion and the awareness of the emerging technologies for corrosion control, prevention, testing and monitoring.
Any module or any combination of modules is available for in-house training and distance learning worldwide. Any module or any combination of modules can be customized to meet the need of your organization.
1.1 Introduction
1.1.1 Definition of corrosion
1.1.2 Types of corrosion
1.1.3 The co$t of corro$ion
1.1.4 Significance of corrosion control
1.2 Electrical concepts relevant to corrosion
1.2.1 Resistivity, conductivity, impedance
1.2.2 Electron conductor, electrolytic (ionic) conductor and semiconductor
1.2.3 Direction of current and flow of electrons
1.3 Matters of Substance
1.3.1 Metals in the melting pot
1.3.2 Defects in metals
1.4 Chemical and electrochemical concepts relevant to corrosion
1.4.1 Ionization of water
1.4.2 Definition of pH
1.4.3 Ionization of metal in water
1.4.4 Electrode process
1.4.5 Anodic and cathodic reactions
1.4.6 Passivation behavior of iron in nitric acid
1.4.7 Standard redox potential
1.4.8 EMF series
1.4.9 Common reference electrodes
1.4.10 The Daniel cell and Galvanic cell
1.4.11 Galvanic series
1.4.12 Essential components in a corrosion cell
1.4.13 Common types of corrosion cells in practical situations
1.4.14 General methods of corrosion control
2.1 Why does a metal corrode? - Thermodynamic aspects of aqueous corrosion
2.1.1 Stable states of metals in nature
2.1.2 The driving force for corrosion
2.1.3 The energy change and the cell potential: Faraday's Law
2.1.4 Effect of concentration: the Nernst Equation
2.1.5 Effect of pH: the E-pH diagram
2.1.6 Practical applications of E-pH diagram and its limitations
2.2 How does a metal corrode? - Kinetics of corrosion
2.2.1 Rate of reaction and rate constant
2.2.2 Factors affect rate of reaction
2.2.3 Anodic and cathodic current densities
2.2.4 Exchange current density
2.2.5 The mixed potential theory
2.2.6 E-log(i) Evans diagram
2.2.7 Tafel Equation and Tafel plot for corrosion rate determination
2.2.8 Linear polarization and Stern-Geary Equation
2.2.9 Type of polarization and rate-controlling step
2.2.10 Concentration polarization and the importance of dissolved oxygen
2.2.11 Effect of oxidizer concentration on rate of corrosion
2.2.12 Effect of velocity on rate of corrosion
3.1 Oxidation of metals & alloys
3.1.1 Mechanisms of ionic movements in metallic oxides
3.1.2 Rate of oxidation and rate laws
3.1.3 Effects of alloying elements on the protective property of oxides
3.2 Oxidation resistance of low-alloy steel
3.2.1 Factors governing oxidation behavior
3.2.2 Oxidation of iron
3.2.3 Alloying effects on oxidation of iron
3.2.4 Stress effects
3.2.5 Commercial low-alloy steels in air or oxygen
3.3 Nature of environments
3.3.1 Air and oxygen
3.3.2 Steam
3.3.3 Sulphur-containing gases
3.3.4 Molten salts
3.3.5 Molten metals
3.4 High temperature corrosion of cast iron
3.5 Corrosion of high-alloy steels
3.6 Nickel and its alloys
3.6.1 Oxidation
3.6.2 Sulphidation
3.6.3 Hot-salt corrosion
3.6.4 Carburisation and attack by carbon-containing gases
3.6.5 Corrosion by molten metals and salts
3.7 Corrosion of advanced ceramics
3.8 Materials for high temperature applications
3.9 Current development and future trend
4.1 Uniform corrosion
4.2 Galvanic corrosion, Dealloying and Graphitisation
4.3 Intergranular stress corrosion cracking, weld decay and knife-line attack
4.4 Crevice corrosion
4.5 Pitting corrosion
4.6 Filiform corrosion
4.7 Microbiologically-influenced corrosion (MIC)
4.8 Environment-sensitive cracking
4.8.1 Stress corrosion cracking (SCC)4.8.2 Hydrogen-induced cracking (HIC)4.8.3 Sulfide stress cracking (SSC)4.8.4 Exfoliation4.8.5 Caustic embrittlement4.8.6 Liquid metal embrittlement (LME)4.9 Corrosion fatigue
4.10 Erosion corrosion, impingement attack and cavitation damge
4.11 Stray current corrosion
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5.1 Corrosion in atmospheres
5.1.1 Type of atmospheres and classification of corrosiveness
5.1.2 Importance of relative humidity on rate of corrosion
5.1.3 Other major factors affect the rate of corrosion
5.1.4 Common forms of corrosion encountered in atmospheres
5.1.5 Corrosion behavior of common engineering materials under atmospheric condition5.1.6 Control and prevention methods
5.2 Corrosion in potable water, natural waters and seawater systems
5.2.1 Compositions of waters5.2.2 Effect of pH5.2.3 Corrosion resistance of common metals and alloys in water systems5.2.4 Corrosion control and prevention methods5.3 Corrosion in Soils
5.3.1 Characterisation of the soil environment5.3.2 Soil resistivity and rate of corrosion5.3.3 Other factors affect the form and rate of corrosion5.3.4 Corrosion resistance of common metals and alloys in soil5.3.5 Corrosion control and prevention methods5.4 Corrosion in Concrete structures
5.4.1 Characteristics of the concrete environment5.4.2 Mechanisms of reinforcement corrosion5.4.3 Control and prevention methods5.5 Current development and future trend
6.1 Design guidelines for corrosion prevention
6.1.1 General classification of materials6.1.2 General classification of environment6.1.3 The natural matching of a material with an environment6.1.4 Good design practice for corrosion prevention6.1.5 Case studies: the Good, the Bad and the Ugly6.2 Corrosion resistance properties of stainless steels and super duplex stainless steels6.2.1 Composition and classification of stainless steels6.2.2 Properties of stainless steels and super duplex stainless steels6.2.3 Effect of alloying elements on the corrosion resistance6.2.4 Composition and structure of passive films on stainless and duplex steels6.2.5 Effects of potential, pH, alloy composition on the stability of passive films6.2.6 Resistance to uniform, localized corrosion and stress corrosion cracking6.2.7 Common engineering applications of stainless and duplex steels6.3 Corrosion resistance of other common engineering materials
6.3.1 Cast iron, carbon steels and low alloys steels
6.3.2 Nickel and nickel alloys
6.3.3 Aluminum and alumium alloys
6.3.4 Copper and copper alloys
6.3.5 Titanium and titanium alloys
6.3.6 Zinc, tin and their alloys
6.4 Corrosion resistance of non-metallic materials
6.4.1 Plastics, rubber, elastomers and vitreous materials
6.4.2 Composite materials
6.4.3 Ceramic materials
6.5 Current development and future trend
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7.1 Metallic coatings
7.1.1 Desired properties of metallic coatings
7.1.2 Type and classification of metallic coatings
7.1.3 Protection mechanisms
7.1.4 Electroplating and electroless plating
7.1.5 Anodizing, phosphating and chromating
7.1.6 Hot-dip galvanizing
7.1.7 Thermal spray
7.1.8 Service life prediction
7.2 Organic coatings: - Paints
7.2.1 Desired properties of organic coatings
7.2.2 Formulation and classification of paints
7.2.3 Protection mechanisms
7.2.4 Surface preparation standards
7.2.5 Methods of application
7.2.6 Corrosion resistance of common paints
7.2.7 Galvanizing vs zinc rich paints
7.2.8 Coatings defects and failure analysis
7.2.9 Service life prediction
7.3 Composite coatings
7.3.1 Formulation and classification of composite coatings
7.3.2 Methods of application
7.3.3 Corrosion resistance properties
7.4 Combined use of organic coatings and cathodic protection
7.4.1 Benefits of the combined systems
7.4.2 Regulatory requirements
7.4.3 Cost analysis
7.4.4 Common applications
7.5 Current development and future trend
8.1 Type, classification and inhibiting mechanisms
8.1.1 Anodic inhibitor
8.1.2 Cathodic inhibitor
8.1.3 Mixed inhibitor
8.2 Formulation of common corrosion inhibitors
8.3 Applications and limitations
8.3.1 Corrosion inhibitor in automotive systems
8.3.2 Inhibitors for cooling water
8.3.3 Inhibitors for potable water system
8.3.4 Corrosion inhibitors for refineries and petrochemical plants
8.4 Volatile corrosion inhibitors (VCI)
8.4.1 Mechanism of protection
8.4.2 Formulation of common VCIs
8.4.3 Applications and limitations
8.4.4 Innovative products based on VCI
8.5 Film-forming rust-proof materials
8.5.1 Type and classification
8.5.2 Applications and limitations
8.6 Control of relative humidity
8.6.1 Critical relative humidity
8.6.2 Effect of atmospheric pollutants
8.7 Deaeration
8.7.1 Solubility of oxygen in liquids
8.7.2 Effect of oxygen content on rate of corrosion
8.7.3 Effect of pH
8.7.4 Effect of temperature
8.7.5 Low pressure and high pressure boiler systems
8.8 Current development and future trend
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9.1 Cathodic Protection: Theory, Practice and Applications
9.1.1 How it works and why it works
9.1.2 Criteria of protection
9.1.3 Sacrificial anode cathodic protection system
9.1.4 Properties of anode materials and selection
9.1.5 Applications of sacrificial anode cathodic protection
9.1.6 Innovative products based on sacrificial anode system
9.1.7 Impressed current cathodic protection system (ICCP)
9.1.8 Properties of anode materials and selection
9.1.9 Instruments for cathodic protection
9.1.10 Cathodic protection in sea water
9.1.11 Cathodic protection in soil
9.1.12 Cathodic protection in concrete structures
9.2 Anodic Protection: Theory, Practice and Application
9.2.1 Theory of anodic protection
9.2.2 System requirements
9.2.3 Criteria of protection
9.2.4 Practical applications
9.3 Cathodic or Anodic, which protection method to use?
9.3.1 Applicable materials
9.3.2 Applicable environments
9.3.3 Effectiveness of protection
9.4 Current development and future trend
10.1 Type and classification of corrosion testing
10.2 The nature of corrosion process
10.3 Conventional methods
10.3.1 Weight loss coupon method
10.3.2 Electrical resistance method
10.4 Electrochemical methods
10.4.1 Linear polarization resistance for determining corrosion rate10.4.2 Potentiodynamic polarization for corrosion behavior analysis10.4.3 Potentiostatic polarization for surface stability analysis10.4.4 Electrochemical potentiokinetic reactivation test for susceptibility to intergranular stress corrosion cracking or weld decay10.4.5 Cyclic polarization test for pitting resistance10.4.6 AC impedance test for corrosion rate measurements and coatings evaluation10.4.7 Zero resistance ammetry (ZRA) test for galvanic corrosion10.4.8 Electrochemical noise for monitoring localized corrosion10.5 Principal online corrosion monitoring techniques
10.5.1 System components and installation strategy
10.5.2 Applications and limitations
10.6 Other methods of corrosion testing and monitoring
10.6.1 Radiographics, ultrasonic and electromagnetic methods
10.6.2 Monitoring water chemistry and corrosion products
10.6.3 Cathodic protection monitoring
10.7 Current development and future trend
