Metallurgy, Corrosion & Prevention of Failures

Course Introduction

This 5-day training program is designed for engineers, maintenance personnel, and project managers who need to understand the principles of metallurgy, corrosion, and the prevention of metal failures. The course will cover the relationship between material properties, corrosion mechanisms, and practical strategies for preventing metal failure, ensuring reliability and longevity of metal structures and equipment in industrial applications.

Objectives

By the end of this course, participants will be able to:

•     Understand the fundamental principles of metallurgy and material properties.
•     Identify the key types of corrosion and their mechanisms.
•     Understand the relationship between metallurgy and corrosion in engineering applications.
•     Learn how to select the appropriate materials to avoid failure and ensure durability.
•     Apply practical corrosion control techniques and failure prevention strategies.
•     Conduct basic failure analysis to diagnose issues and prevent future occurrences.

Target Audience

•    Mechanical, Civil, and Structural Engineers
•     Maintenance and Reliability Engineers
•     Operations Managers
•     Project Managers and Designers
•     Technicians and personnel involved in materials handling and metal processing
•     Anyone involved in manufacturing, construction, oil & gas, and energy sectors

Daily Topics

Day 1: Introduction to Metallurgy and Material Properties

    Overview of metallurgy: The science of materials

    Understanding material structure: Atomic structure, crystal lattices, and grain boundaries

    Mechanical properties of materials: Strength, hardness, ductility, and toughness

    Types of materials: Ferrous and non-ferrous metals, alloys, and composites

    Importance of selecting the right material for specific applications

Workshop: Identifying materials based on their properties and applications in different industries

Day 2: Corrosion Mechanisms and Types

    What is corrosion? Understanding the basic principles and causes

    Types of corrosion: Galvanic, pitting, crevice, stress corrosion cracking (SCC), and uniform corrosion

    Factors influencing corrosion: Environmental conditions, material composition, and design flaws

    Electrochemical corrosion and its impact on metal components

    The effect of temperature, pressure, and chemical exposure on corrosion rates

Case Study: Understanding real-world examples of corrosion failures and their root causes

Day 3: Corrosion Prevention Techniques

    Material selection to prevent corrosion: Choosing resistant materials and alloys

    Coating techniques: Paint, galvanizing, anodizing, and cladding

    Use of corrosion inhibitors in coatings and treatments

    Introduction to cathodic protection and sacrificial anodes

    Best practices for environmental control to reduce corrosion risks

    Role of design in minimizing corrosion risks (e.g., proper drainage, avoiding crevices)

Workshop: Applying corrosion prevention methods to a simulated real-world scenario

Day 4: Metallurgical Failures and Analysis

    Common causes of metal failures: Fatigue, brittle fracture, wear, and stress corrosion

    Introduction to failure analysis: Techniques for diagnosing failures (visual inspection, NDT methods, fracture analysis)

    Fatigue failure: Causes, types, and prevention strategies

    Stress corrosion cracking (SCC): Mechanisms and prevention

    Wear and abrasion: Managing wear in moving parts

    Impact of welding and fabrication processes on the likelihood of failures

Practical Session: Hands-on demonstration of failure analysis using case studies and sample materials

Day 5: Maintenance Strategies for Preventing Failures

    Preventive maintenance approaches for minimizing metal failures

    Developing inspection routines for corrosion and metal degradation

    Role of lubrication in minimizing wear and tear

    Conducting regular non-destructive testing (NDT) to detect early signs of failure

    Managing spare parts and inventory for critical equipment

    Best practices for systematic troubleshooting and corrective actions

Final Project: Group work: Identifying and solving a corrosion or failure issue from a given industrial scenario

Assessment:

•     Daily quizzes and knowledge checks
•     Practical exercises and hands-on sessions
•     Final group project and presentation

Certification:

Upon successful completion of the course, participants will receive a Certificate in Metallurgy, Corrosion & Prevention of Failures.

For registration & more information please contact

NAYEL Training Centre 

T: +971 4 5587735 | M: +971 54 7962098 |WhatsApp: +971 54 7962098

Email:  info@nayeltraining.com