Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Mechanical, Metallurgical, and Chemical Engineers
• Maintenance and Reliability Engineers
• Corrosion and Integrity Engineers
• Inspection and Quality Control Personnel
• Project and Design Engineers
• Anyone involved in materials selection, surface protection, or corrosion management

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

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

• Understand the relationship between metallurgy, corrosion, and coating performance
• Identify material degradation mechanisms and contributing environmental factors
• Select appropriate metallic materials for corrosion-resistant design
• Evaluate and apply coating systems for corrosion prevention
• Interpret inspection results and failure analysis reports
• Develop effective material protection and corrosion management plans

DAY 1

Introduction to Metallurgy and Material Behavior

• Welcome and Introduction
• Pre-Test
• Overview of Material Science and Metallurgical Principles
• Microstructure of Metals and Alloys
• Effects of Alloying Elements on Material Properties
• Heat Treatment and Its Role in Corrosion Resistance
• Material Selection Criteria for Industrial Applications
• Common Metallurgical Failures in Service

DAY 2

Corrosion Fundamentals and Mechanisms

• Basic Electrochemical Principles of Corrosion
• Types of Corrosion: Uniform, Galvanic, Pitting, Crevice, and Intergranular
• Environmental Factors Affecting Corrosion Rate
• Role of Metallurgical Structure in Corrosion Susceptibility
• Corrosion in Different Media (Water, Soil, Atmosphere, Chemicals)
• Microbiologically Influenced Corrosion (MIC)
• Case Studies: Metallurgical Effects on Corrosion Behavior

DAY 3

Corrosion Prevention and Control Techniques

• Corrosion Prevention Through Design and Material Selection
• Cathodic and Anodic Protection Methods
• Use of Corrosion Inhibitors and Control Chemicals
• Surface Treatments and Heat Treatments for Corrosion Resistance
• Inspection and Monitoring of Corrosion (Visual, NDT, Electrochemical)
• Risk-Based Corrosion Management Approaches
• Case Studies on Corrosion Control Programs

DAY 4

Protective Coatings and Surface Engineering

• Overview of Coating Systems and Their Functions
• Types of Coatings: Metallic, Inorganic, Organic, and Composite
• Surface Preparation and Application Techniques
• Coating Selection for Various Industrial Environments
• Testing and Evaluation of Coating Performance
• Failure Modes in Coating Systems and Root Cause Identification
• Advances in Surface Engineering and Nano-Coatings

DAY 5

Integration of Metallurgy, Corrosion, and Coating Practices

• Coordinating Metallurgical Design, Corrosion Control, and Coating Application
• Maintenance and Inspection Strategies for Long-Term Protection
• Life-Cycle Cost Analysis for Corrosion and Coating Systems
• Review of Industry Codes and Standards (ASME, ISO, NACE)
• Post-Test
• Certificate Ceremony