MEng Materials Science and Engineering

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.

• 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.

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

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.

• 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.
• 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.
• 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.
• 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. 

• Explain both general and localised corrosion/damage processes and the reasons for these occurring in industrial processes.
• Evaluate high-temperature corrosion and oxidation processes on metallic systems, and determine how the environmental degradation might affect performance in service.
• 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.
• Apply management of corrosion by design, material fabrication and materials selection to optimize materials performance in energy systems. 

• Apply electrochemical equipment to evaluate the localised corrosion resistance of structural alloys as a function of their environment.
• Explore and analyse the different forms of material degradation.

• Justify technical arguments in a clear fashion.
• Use appropriate vocabulary to answer technical questions and prepare laboratory reports.
• Operate as an effective team member.

Written and verbal

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/informationandadviceonlink2listsreadinglistsoftware/

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