Metal Corrosion and Its Prevention
I.D. # 99006 Duration 2 Days
Corrosion accounts for billions of dollars in losses to a variety of metallic structures and products annually. This seminar provides insight into corrosion, its underlying causes, and potential solutions, topics which are important to all engineers involved with the design and specification of metal components and structures.

Elementary concepts related to the more common types of corrosion will be reviewed, as well as the various methods available for minimizing corrosion in metals. This course will conclude by examining at least two corrosion case histories of interest to engineers involved in transportation vehicle design.

Types of corrosion to be described in this seminar include galvanic corrosion (dissimilar metals), concentration cell corrosion, crevice corrosion, stress corrosion, and corrosion-assisted fatigue. In addition, "uniform" corrosion will be discussed as it applies to such common occurrences as the general rusting of steel. Methods of corrosion protection include cathodic protection from sacrificial anodes and impressed DC voltage, anodic protection, inhibitors, and coatings. The effectiveness and limitations of these techniques will be discussed.

Learning Objectives
By attending this seminar, you will be able to:
  • Describe the basic electrochemical concepts of corrosion
  • Identify the primary methods that can be used to prevent or minimize corrosion
  • Define the nature of an actual corrosion problem and recommend a workable solution
Who Should Attend
Automotive, aircraft, off-highway and marine engineers involved in design, production, and quality functions that have an interest in corrosion and corrosion prevention in metal components and assemblies will benefit from this seminar. Since corrosion can only be adequately understood from electrochemical considerations, it is strongly recommended that each attendee has completed at least a one-semester course in college chemistry in which he/she was introduced to basic electrochemistry.
Seminar Content

DAY ONE

  • General Introduction to Corrosion
  • Electrochemical Nature of Corrosion
    • Anode-cathode relationships
    • Electrode potentials
    • Electromotive and galvanic series
  • Rates of Corrosion
    • Measurement and specification
    • Polarization effects
    • Prediction
    • Passivity and environmental effects
  • Corrosion Cells
    • Metal composition
    • Electrolyte concentration
    • Stress
  • Forms of Corrosion
    • Uniform attack
    • Galvanic (dissimilar metals)
    • Crevice Corrosion
    • Pitting
    • Intergranular attack
    • Corrosion-assisted fatigue
    • Stress corrosion and hydrogen embrittlement
  • Corrosion Problems and Calculations (Workgroups)

DAY TWO

  • Corrosion Environments
    • H2O and aqueous solutions
    • Acids and bases
    • NaCl and seawater
  • Methods of Corrosion Prevention
    • Overview
    • Component design
    • Coatings
    • Cathodic protection
    • Anodic protection (passivation)
    • Inhibitors
    • Materials selection and treatment
  • Video - "Corrosion in Action"
  • Case Studies in Corrosion of Metals
    • Corrosion in the automotive industry
    • Corrosion in aluminum and aluminum alloys
    • Steel weldment corrosion
  • Summary and Open Discussion
Instructor(s): Darrell W. Smith
Dr. Darrell Smith is a consultant in metallurgy and materials and is Professor Emeritus of Metallurgical Engineering at Michigan Technological University. Prior to joining the faculty at MTU, he was employed as a process metallurgist by Babcock and Wilcox and as a research metallurgist by General Electric. Dr. Smith has conducted extensive continuing education seminars related to metals and materials and engineering, including corrosion and oxidation. He has published approximately 50 research papers in archival journals related to specific aspects of materials science and engineering. Dr. Smith, a Fellow of ASM International and APMI International, has served on the Boards of Directors for both organizations. He is the recipient of the Distinguished Educator Award from ASM and the Distinguished Service to Powder Metallurgy Award from the Metal Powder Industries Federation. Dr. Smith has a B.S.-Met E. from Michigan Technological University and a M.S.-Met. and Ph.D. from Case Western Reserve University.
Testimonial
"This course provided me with the necessary concepts to move ahead in my understanding and control of product in a production environment."
Shane A. Barber
Engineer, Chemical Management
Henkel Surface Technolgies

"Fantastic overview of metal corrosion, the causes and how to apply basic principles to prevent."
Mattew J. Heyen
Development Engineer
Mercedes-Benz U.S. International

"An excellent overview of fundamental metal corrosion mechanisms."
Dustin Parks
Associate Technical Specialist
Honda Manufacturing of Alabama

"I have a clear conceptual and foundational understanding of Metal Corrosion to build on now."
Calvin Winston
Associate Technical Specialist
Honda Manufacturing of Alabama

Fees: $1225 SAE Members*: $980 - $1103
* The appropriate SAE Member discount will be applied through the Registration process.  Discounts vary according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%
CEU 1.3