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MSc Corrosion Control Engineering / Course details

Year of entry: 2020

Course unit details:
Corrosion & Control for Industrial Processes

Unit code MATS66502
Credit rating 15
Unit level FHEQ level 7 – master's degree or fourth year of an integrated master's degree
Teaching period(s) Semester 2
Offered by Department of Materials
Available as a free choice unit? No

Overview

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. 

Aims

To enable to students to understand the corrosion challenges faced by the Process and Power Industries. • To enable students to understand how materials selection and the design and use of countermeasures to combat corrosion are commonly used in industry. • To ensure students understand the specific corrosion challenges in cooling and steam raising equipment • 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.

Learning outcomes

A greater depth of the learning outcomes will be covered in the following sections:

• Knowledge and understanding

• Intellectual skills

• Practical skills

• Transferable skills and personal qualities

Teaching and learning methods

Lectures, group tutorials (problem sessions), recommended textbooks, web resources, self- teaching worked examples, past exam papers, electronic supporting information (Blackboard).

 

Knowledge and understanding

High Temperature

State the structure, thickness and composition of passive films on various materials, and understand how these are determined.

Rationalise the approximate potential and pH ranges of passivity using thermodynamics

List the factors that affect the oxidation of alloys.

Account for the origins of internal stresses in oxide scales.

Describe the mechanisms of carburization and metal dusting, and identify associated corrosion product morphologies.

Describe corrosion processes in high temperature industrial environments such as fossil fuel power plant.

Describe thermal barrier coatings to protect structures from high temperature corrosion.

SCC

Understand the most common types of stress corrosion cracking, the effects of stress, metallurgy and environment on SCC rates and occurrence.

Acids and Alkalis

Understand the mechanisms of corrosion in sulphuric acid or caustic solutions and the types of materials that resist these environments.

Explain the corrosion behaviour of steel reinforcement in concrete

Localised Corrosion

Quantify the relationship between pitting and crevice corrosion, and relate this to the effects of deposits

Describe the factors that affect molten-salt corrosion and account for the reaction kinetics.

Nuclear Power

Understand the treatments used for water in nuclear power generation, and environments and types of failure that may be encountered in such systems.

Failure Assessment methods

Understand the construction and use of Failure Assessment Diagrams to predict safe operation regimes for plant equipment. 

Intellectual skills

Describe the effects of stress corrosion cracking on materials and list the tests used to assess materials’ susceptibility to these effects.

Understand both general and localised corrosion/damage processes and the reasons for these occurring.

Use a Failure assessment Diagram to predict to the safety of a piece of equipment for a given set of conditions

Practical skills

Set up and monitor a localised corrosion experiment. 

Transferable skills and personal qualities

The practical exercises include teamwork exercises to develop students experience of collaborative working.

Students will gain experience of microscopy, and will use SEM images of their samples for their report

Assessment methods

Method Weight
Other 15%
Written exam 70%
Report 15%

Online Quiz

Feedback methods

Feedback given verbally and written.

Recommended reading

General texts are listed in the reading list for unit MATS63351. More specialist topics are covered in this unit, but many of these works are also useful for this unit.   Electrocorrosion and Protection of Metals General approach with particular consideration to electrochemical plants Joseph Riskin Burlington : Elsevier Science 2008 Online access available   Corrosion and Chemical Resistant Masonry Materials Handbook William Andrew Publishing/Noyes 1986 Online 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. Cheremisinoff Westwood, N.J. : Noyes Publications ©1996 Online access available   Handbook of environmental degradation of materials / edited by Myer Kutz. Myer Kutz Waltham, MA : William Andrew 2nd ed. 2013 Online access available   Environmentally assisted cracking : predictive methods for risk assessment and evaluation of materials, equipment, and structures / Russell D. Kane, editor. R. D Kane W. Conshohocken, PA : ASTM 2000 Available at Joule Library Main Level (620.182 KAN )   Treatment of Cooling Water / by Aquaprox. Aquaprox. author. SpringerLink (Online service) Springer eBooks Berlin, Heidelberg : Springer Berlin Heidelberg, 2009 Online access available   Selection and use of engineering materials. J. Charles F. A. A Crane (Frederick Albert Andrew), 1927-1984.; J. A. G Furness Oxford : Butterworth-Heinemann 3rd ed. / J.A. Charles, F.A.A. Crane, J.A.G. Furness. 1997 Online 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 eBooks London : Springer London : Imprint: Springer, 2013   Online access available For Information and advice on Link2Lists reading list software, see: 

"http://www.library.manchester.ac.uk/academicsupport/informationandadviceonlink2listsreadinglistsoftwar"http://www.library.manchester.ac.uk/academicsupport/informationandadviceonlink2listsreadinglistsoftware/

Study hours

Scheduled activity hours
Lectures 30
Independent study hours
Independent study 120

Teaching staff

Staff member Role
Nicholas Stevens Unit coordinator

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