Corrosion Research at the Materials Technology Institute 2009 NACE Regional Pittsburgh Tony Scribner

4/18/2015MTI presentation24/18/20152 Summary  Brief History  Organization  Key Benefits

4/18/2015MTI presentation3 A Brief History of MTI  5 Guys in a Bar  NACE 1975 Toronto  Discussing Major Problem Areas  Inadequate Resources  Result—Frustration, then an Idea! 4/18/20153

MTI presentation4 Frustration—Then An Idea!  Why Not Pool Funds for Solving Generic Problems?  And the Rest is 35 Years of History! 4/18/20154

MTI presentation5 MTI Staff 6 Directors  Tony Scribner, WV  Barry Greene, NJ  Emory Ford, MA  Galen Hodge, IN  Heather Stine, NH  Jim Macki, WA Staff Consultant  Jesse Chen St. Louis Office  Debby Ehret  Lori Elgin  Katherine Reinecke 4/18/20155

MTI presentation6 Operating Philosophy Members define activities  Staff helps make it happen  Operating mode is “town meeting”  Technical issues—TAC’s, PDC’s, & PT’s Avoid “staff driven” Require “champions ” 4/18/20156

MTI presentation7 Some of the Current Programs at MTI  Terahertz Imaging to Identify Defects in FRP and Detect CUI  Guidelines for Assessing Fire and Explosion Damage – 2 nd Edition of Publication No. 30  Operation, Maintenance and Repair of Glass Lined Equipment

4/18/2015MTI presentation8 Some of the Current Programs at MTI Page 2  Understanding Metal Dusting and the Development of MD Resistant Alloys  Detection of Hydrogen in Titanium  Improvements in Metal Casting Quality

4/18/2015MTI presentation9 Terahertz Imaging to Detect Damage in FRP Structures and Detect CUI  Program just finishing at RPI to leverage the THz imaging technology used in security programs to CPI use.  Detection of laminar defects in FRP in a manner similar to that used by NASA on the Space Shuttle  Detection of corrosion under insulation

4/18/2015MTI presentation10 Detection of Inch Thick Laminar Defect in Polyester Resin FRP

4/18/2015MTI presentation11 Detection of Corrosion Under Insulation

4/18/2015MTI presentation12 Detection of Corrosion Under Insulation

4/18/2015MTI presentation13 Guidelines for Assessing Fire and Explosion Damage  First published 1990  2 nd Printing 1992  Incorporated into API 579  Expanded 2 nd Edition now in preparation

4/18/2015MTI presentation14 Arson and Sabotage  Must never be mentioned lightly  Turns an incident site into a crime scene  Most companies hate to talk about it for fear of copycats  More common than one might think

4/18/2015MTI presentation15 Arson and Sabotage

4/18/2015MTI presentation16 Arson and Sabotage

4/18/2015MTI presentation17 Storm Damage  Notorious 2005 Hurricane season made it clear that storm damage assessment was as important as fire or explosion damage assessment  Storm damage assessment similar to fire damage assessment  Balance early return to service with safe reliable operation

4/18/2015MTI presentation18 Storm Damage

4/18/2015MTI presentation19 Wind Damage

4/18/2015MTI presentation20 Operation, Maintenance and Repair of Glass Lined Equipment  New book that has just been published  Written by industry experts  Details inspection and assessment of GLS  Liberally illustrated with repair types and repair instructions

4/18/2015MTI presentation21 Installation of One Piece Agitator

4/18/2015MTI presentation22 Describes the Various Failure Modes Example of Thermal Shock

4/18/2015MTI presentation23 Illustrated Repair Techniques 3 Piece Plug

4/18/2015MTI presentation24 Illustrated Repair Techniques Plug Installation

4/18/2015MTI presentation25 Illustrated Repair Techniques Plug Installation

4/18/2015MTI presentation26 Understanding Metal Dusting  Expert review of the various theories that are used to explain metal Dusting  JV with the National Laboratories for modeling Metal Dusting  Testing of various alloys for resistance to Metal Dusting  Development of a new alloy

4/18/2015MTI presentation27 Understanding Metal Dusting

4/18/2015MTI presentation28 Metal Dusting Alloy Testing

4/18/2015MTI presentation29 Metal Dusting Alloy Development Argonne National Laboratory  Cr25%  Al 3%  Zr 0.1%  Y 0.1%  Fe< 1%  NiBal

4/18/2015MTI presentation30 Continuing Research into Metal Dusting  Understand the effects of additives to the gas streams to slow or eliminate metal dusting  Understand the effects of surface coatings that either protect the metal surface or poison the metal dusting reaction.

4/18/2015MTI presentation31 Detection of Hydrogen in Titanium  Hydrided titanium can be “glass” brittle  It looks the same as non-hydrided titanium  MTI members would like a simple NDT technique to be able to detect hydriding

4/18/2015MTI presentation32 Detection of Hydrogen in Titanium

4/18/2015MTI presentation33 Detection of Hydrogen in Titanium  Contracted to develop a simple tool to detect hydrogen  Electrical resistance change based  Technique has led to another, alternative technique that may be more sensitive

4/18/2015MTI presentation34 Casting Quality Prediction  Problems:  Presence of intergranular solidification shrink that X-rays can not find.  This produces leaks when in service.  Reduces yield of casting process  Need:  Quantitative process to predict formation of shrink and how to correct.

4/18/2015MTI presentation35 Casting Quality Prediction .. Leak M35 -1 Casting

4/18/2015MTI presentation36 Niyama Values in Region of Leak mid-plane ID OD Ny min = 0.69 Ny min = 0.58 Niyama values are in units of (°C-s)1/2/mm

4/18/2015MTI presentation37 Casting Quality Prediction  Objectives of Program  Create data necessary for all important CPI alloys  Develop a procedure that can be used to validate the capability of a foundry to use the Niyama simulation

4/18/2015MTI presentation38 MTI Sponsored Research  Projects that improve industrial competitiveness  Covers a wide variety of subjects that are important to members  Done by pooling funding to develop and understand materials and corrosion issues that are of common interest  Membership is open to all companies.