Metallurgy, Materials Selection and Corrosion

What are the Goals?

At the end of this Metallurgy, Materials Selection and Corrosion training course, the participants will be able to:

• Gain a sound understanding of the properties and applications of materials with particular emphases on the oil and gas industries
• Obtain a good appreciation of material selection methods and criteria
• Develop a good knowledge, understanding and be able to select major types of engineering metals, including, carbon steels, alloy steels, stainless steels, cast irons, copper and brass alloys, titanium and nickel based alloys
• Select heat treatment processes and mechanical strengthening techniques for metals, in order to optimise their use in a variety of engineering applications
• Appreciate the selection of nonmetals, including polymers that are used for corrosion protection coatings and liners.
• Gain a working knowledge of the following:
• Corrosion issues
• Various types of corrosion
• Good appreciation of material selection as a method of corrosion control and mitigation
• Explain the mechanisms behind corrosion resistant materials
• Be able to evaluate the performance and the selection of materials, coatings and inhibitors for various situations involving corrosion
• Develop a working knowledge and selection of materials for major failure and degradation mechanisms, including different types of stress and elevated temperature conditions.
• Be able to select materials for specific applications such as piping, valves, pressure vessels, equipment and welding.
• obtain a good knowledge of destructive and non-destructive testing of metals

Who is this Training Course for?

This Metallurgy, Materials Selection and Corrosion training course is intended for those who use or supervise activities requiring the selection, design/fabrication or use of materials, component parts or structures. Those with little or no prior formal background who function as:

• Managers
• Supervisors
• Engineers
• Planners
• Inspectors
• Designers
• Researchers
• Investors
• Procurers
• Who seek a basic understanding of materials and the practical aspects of materials selection, evaluation and procurement should find this training course valuable.

Daily Agenda

Day One:  Materials Destructive Testing, Properties & Selection

• Destructive materials testing – Tensile, Impact (Izod and Charpy), Hardness
• Types of failures – Ductile/brittle, temperature effects
• Analytical tools – visual examination of fracture surface
• Materials selection based on mechanical properties and standard tables

Day Two: Crystalline Structure of Metals and Phase Diagrams

• Atomic bonding of materials - metallic bonding, ionic bonds, covalent bonding of polymers, bonding energy and inter-atomic spacing
• Basic metallic structures - polymorphic transformation of metals, crystal growth and overall bulk solidification, of metals, defects in metals during solidification      
• Dislocations and selection of mechanisms of strengthening in metals - imperfections in crystals, properties of dislocations, strengthening by cold working, grain refinement and alloying, residual stresses in metals       
• Phase diagrams - solubility, solid solution, diffusion

Day Three: Ferrous And Non-Ferrous Alloy Properties, Heat Treatment and Selection

• Ferrous alloys, selection and heat treatment – micro-structure of carbon steel, heat treatment of steel, hardening of carbon steel (by quenching), critical cooling rate and mass effect, hardenability of steel; the jominy (end-quench), annealing
• Ferrous alloys - classification of carbon steels, low-carbon steels, medium-carbon steels, high-carbon and tool steels, alloy steels, the need for alloying, alloying elements, stainless steel, general properties and classification, ferritic stainless steel, austenitic stainless steel, martensitic stainless steels, duplex stainless steel, full stainless steel technical data, cross reference of stainless-steel standards
• Cast irons – types and selection, corrosion and temperature resistance of cast irons
• Selected welding processes, welding microstructure, heat affected zone (HAZ), selected weld defects
• Copper based alloys, nickel and cobalt - general characteristics, nickel and monel, super alloys, selection for corrosion and elevated service temperature
• Titanium alloys - types of titanium alloys (α, β and αβ), processing and selection of titanium alloys for corrosion resistance
• Materials selection in different environments

Day Four: Corrosion and Other Failures and Materials Selection For Failure Minimisation

• Corrosion and materials selection - the electrochemical cell, general corrosion (uniform corrosion), galvanic corrosion (composition cell), crevice corrosion (concentration cell, corrosion under insulation, surface-to-air corrosion), pitting corrosion, Impingement attack corrosion (erosion corrosion), stress corrosion cracking (SCC), inter-granular corrosion
• Corrosion under different environments, H2, H2S, Cl, Caustic
• Corrosion protection by, inhibitors, coatings, cathodic protection
• Relevant Standards - NACE

Day Five: Non-Destructive Testing

• Boroscope
• Dye penetrant
• Magnetic methods
• X-ray methods
• Gama-ray methods
• Ultra-sonic methods
• Eddy current testing
• Intelligent pigging