Corrosion Control for Industrial Practice

MATS66502 Corrosion Control for Industrial Practice 15 Semester 2 Postgraduate Taught Level 7 Xiaorong Zhou Unit coordinator Department of Materials 1 FHEQ level (Framework for Higher Education Qualifications) ' Masters/Integrated Masters P4 ' European Credit Transfer & Accumulation System Rating : 7.5 This unit provides students with an understanding of the key corrosion processes and mechanisms of preventing these for the Process and Power industries, covering topics such as high temperature corrosion and moving on to environmentally induced cracking and localised corrosion.  This unit provides students with an understanding of the key corrosion processes and mechanisms of preventing these for the Process and Power industries, covering topics such as high temperature corrosion and moving on to environmentally induced cracking and localised corrosion. The unit shows students how these modes of failure might be encountered in industrial and power plant environments. The corrosion risks for combinations of engineering materials and environments including humid air, steam, hot water, acids, and alkalis are presented and discussed. The cross cutting themes are the prediction of corrosion risks in the different environments, the use of design and materials selection to minimise the probability of corrosion failures, and to encourage an appreciation of the strengths and weaknesses of the different corrosion control strategies available.A final set of lectures considers how corrosion data is used to by engineers from other disciplines, and shows how information from corrosion engineers is used in Failure Assessment Diagrams, where both structural engineering concepts and information on rates of degradation of structures can be integrated to provide robust techniques to assess the integrity and lifetimes of industrial plant and equipment. To enable to students to understand the corrosion challenges faced by the Process and Power Industries.<ul> <li>To enable students to understand how materials selection and the design and use of countermeasures to combat corrosion are commonly used in industry.</li> <li>To ensure students understand the specific corrosion challenges in cooling and steam raising equipment</li> <li>To enable students to use the R6 Failure Assessment Diagram framework to integrate data on corrosion risks with mechanical and structural design and assessment methods.</li></ul>  A greater depth of the learning outcomes will be covered in the following sections: <ul> <li> Knowledge and understanding</li> <li> Intellectual skills</li> <li> Practical skills</li> <li> Transferable skills and personal qualities</li> </ul> <ul><li>Explain how the structure, thickness and composition of passive films develop on various metallic materials and interpret their importance on localized corrosion and environmentally assisted fracture. Quantify the relationship between pitting and crevice corrosion, and relate this to the effects of depositsEvaluate the corrosion behaviour of structural alloys in hot water, acids, alkalis and salts using science based corrosion maps. Draw diagrams and use appropriate equations illustrating the different factors that affect corrosion rate.</li><li>Recognise the main forms of environmentally assisted fracture (including stress corrosion cracking, hydrogen embrittlement and corrosion fatigue) occurring in industrial processes and energy systems. Identify suitable testing methods and mitigation applied to materials commonly used for structural applications.</li><li>Explain the factors that affect the high-temperature oxidation behaviour of structural alloys in industrial environments, including gas turbines, power plants, heat exchangers and thermal energy storage plants.</li><li>Describe the mechanisms of carburization and metal dusting, identify associated product morphologies and propose potential protection strategies. Compare the corrosion kinetics and product characteristics of oxidation and sulphidation reactions. Evaluate the factors that affect molten-salt corrosion processes and account for the reaction kinetics. </li></ul> <ul><li>Explain both general and localised corrosion/damage processes and the reasons for these occurring in industrial processes.</li><li>Evaluate high-temperature corrosion and oxidation processes on metallic systems, and determine how the environmental degradation might affect performance in service.</li><li>Relate how material degradation mechanisms can affect component life-time behaviour. Gain an appreciation of the influence of different types of environment on corrosion/oxidation processes.</li><li>Apply management of corrosion by design, material fabrication and materials selection to optimize materials performance in energy systems. </li></ul> <ul><li>Apply electrochemical equipment to evaluate the localised corrosion resistance of structural alloys as a function of their environment.</li><li>Explore and analyse the different forms of material degradation.</li></ul> <ul><li>Justify technical arguments in a clear fashion.</li><li>Use appropriate vocabulary to answer technical questions and prepare laboratory reports.</li><li>Operate as an effective team member.</li></ul> The course is delivered via face-to-face activities supported by online teaching material and resources. This material was originally developed as an online version of the course, but now serves as a parallel resource for self-study and revision, with tests and other activities students may use.There will be a formative online quiz for practise in the third week of teaching, followed by an assessed quiz activity after the fourth week of teaching (week 22). The final assessed coursework is a lab exercise, to examine Pitting Corrosion. This will be a group report. 1 Written exam 70% 2 Written assignment (inc essay) 30% Written and verbal N <div>General texts are listed in the reading list for unit MATS63301. More specialist topics are covered in this unit, but many of these works are also useful for this unit.</div><div> </div><div>Shreir's Corrosion, Four-Volume - 2009 by Tony Richardson (Author), Tony J.A. Richardson (Editor), Bob R A Cottis (Editor) https://www.sciencedirect.com/book/9780444527875/shreirs-corrosion</div>Electrocorrosion and Protection of Metals General approach with particular consideration to electrochemical plantsJoseph RiskinBurlington : Elsevier Science 2008Online access available  Corrosion and Chemical Resistant Masonry Materials HandbookWilliam Andrew Publishing/Noyes 1986Online access available  Understanding how components fail / Donald J. Wulpi.Donald J. Wulpi author. Brett Miller Metallurgical engineer, editor.Materials Park, Ohio : ASM International, Third edition / edited by Brett Miller. 2013]Online access available  Materials selection deskbook / by Nicholas P. Cheremisinoff.Nicholas P. CheremisinoffWestwood, N.J. : Noyes Publications ©1996Online access available  Handbook of environmental degradation of materials / edited by Myer Kutz.Myer KutzWaltham, MA : William Andrew 2nd ed. 2013Online access available  Environmentally assisted cracking : predictive methods for risk assessment and evaluation of materials, equipment, and structures / Russell D. Kane, editor.R. D KaneW. Conshohocken, PA : ASTM 2000Available at Joule Library Main Level (620.182 KAN )  Treatment of Cooling Water / by Aquaprox.Aquaprox. author. SpringerLink (Online service)Springer eBooksBerlin, Heidelberg : Springer Berlin Heidelberg, 2009Online access available  Selection and use of engineering materials.J. Charles F. A. A Crane (Frederick Albert Andrew), 1927-1984.; J. A. G FurnessOxford : Butterworth-Heinemann 3rd ed. / J.A. Charles, F.A.A. Crane, J.A.G. Furness. 1997Online access available. The library also has physical copies.  Materials for Nuclear Plants From Safe Design to Residual Life Assessments / by Wolfgang Hoffelner.Wolfgang Hoffelner author. SpringerLink (Online service)Springer eBooksLondon : Springer London : Imprint: Springer, 2013Online access availableFor Information and advice on Link2Lists reading list software, see:<a href="http://www.library.manchester.ac.uk/academicsupport/informationandadviceonlink2listsreadinglistsoftware/">http://www.library.manchester.ac.uk/academicsupport/informationandadviceonlink2listsreadinglistsoftware/</a> Lectures 30 Tutorials 3 0 117