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Cutting the Cost of Corrosion
- Materials Selection and Design (3 days) 

Proper selection of materials and design are most effective in cutting the cost of corrosion and achieving lost cost reliability. The theme throughout this course is how to put the right material in the right place in the right way.

Course Objectives    
Course Contents
Who Should Attend   
Course Lecturer

Created in July 1995 last updated 24 July 1998

COURSE OBJECTIVE

This is the third in the corrosion course series and the major objectives of this module are to provide an appreciation of the art and technology in cutting the cost of corrosion by materials selection and design, and the technical know-how of achieving low cost reliability.

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COURSE CONTENT

CORROSION, a major but controllable hidden loss-maker, is in many cases unrecognized and unaddressed. It is often camouflaged under "planned maintenance", pigeonholed as "unscheduled downtime", and paid for in lost production, reduced efficiency, contaminated products, damaged equipment, or even loss of life. It has been shown that the cost of corrosion and the attempts to combat it amount to 3.5% of the National Gross Product of many Western countries, equivalent to several billions of dollars every year. If management is fundamentally concerned with maximising profit, no manager can afford to ignore corrosion.

Proper selection of materials and design are most effective in cutting the cost of corrosion and achieving low cost reliability as corrosion can be designed out of the system. It is always easier and cheaper to erase lines on a drawing than to repair or replace failed equipment or components in service. The theme throughout the course will be focused on how to put the right material in the right place in the right way. Numerous case histories of real-life problems and practical solutions will be presented, including the following materials, environments and corrosion failures:

• materials: carbon steel (unprotected carbon steels, galvanized steels, coated carbon steels), low alloy steel, stainless steel, nickel and high nickel alloys, copper and its alloys, aluminum and its alloys, titanium, tantalum, zirconium, cast alloys;
• environments: steam and steam condensate systems, gas turbines, heating systems, cold and hot tapwater systems, cooling water systems, water/gas/air treatment and purification systems, marine installations (production, storage and transport), civil constructions;
• failures: pitting, crevice corrosion, chloride attack, galvanic corrosion, deposit attack, graphitization, stress corrosion cracking, exfoliation, erosion and cavitation, atmospheric corrosion, corrosion underneath insulation, weld decay, superheating attack.

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WHO SHOULD ATTEND

This course has been designed for the technologists, engineers and designers who are concerned with corrosion prevention but do not have the necessary background knowledge. Very extensive use of case histories and practical examples in this course has reduced the corrosion theory to a minimum so that any technical personnel will be able to appreciate the technical know-how of preventing corrosion by materials selection and design. It is also suited for those whose work involves any of the following: materials evaluation, materials selection, design, failure analysis, quality assurance, process control and maintenance.

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