Corrosion Research at the Materials Technology Institute

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

Summary Brief History Organization Key Benefits 4/1/2014 MTI presentation 2

A Brief History of MTI 5 Guys in a Bar NACE 1975 Toronto Discussing Major Problem Areas Inadequate Resources Result—Frustration, then an Idea! 4/1/2014 MTI presentation 3

Frustration—Then An Idea! Why Not Pool Funds for Solving Generic Problems? And the Rest is 35 Years of History! 4/1/2014 MTI presentation 4

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 4/1/2014 MTI presentation St. Louis Office Debby Ehret Lori Elgin Katherine Reinecke 5

Operating Philosophy Members define activities Avoid “staff driven” Require “champions” • Staff helps make it happen • Operating mode is “town meeting” • Technical issues—TAC’s, PDC’s, & PT’s 4/1/2014 MTI presentation 6

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

Some of the Current Programs at MTIPage 2 • Understanding Metal Dusting and the Development of MD Resistant Alloys • Detection of Hydrogen in Titanium • Improvements in Metal Casting Quality MTI presentation

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 MTI presentation

Detection of 0.010 Inch Thick Laminar Defect in Polyester Resin FRP MTI presentation

Detection of Corrosion Under Insulation MTI presentation

Guidelines for Assessing Fire and Explosion Damage • First published 1990 • 2nd Printing 1992 • Incorporated into API 579 • Expanded 2nd Edition now in preparation MTI presentation

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 MTI presentation

Arson and Sabotage MTI presentation

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 MTI presentation

Storm Damage MTI presentation

Wind Damage MTI presentation

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 MTI presentation

Installation of One Piece Agitator MTI presentation

Describes the Various Failure ModesExample of Thermal Shock MTI presentation

Illustrated Repair Techniques3 Piece Plug MTI presentation

Illustrated Repair TechniquesPlug Installation MTI presentation

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 MTI presentation

Understanding Metal Dusting MTI presentation

Metal Dusting Alloy Testing MTI presentation

Metal Dusting Alloy DevelopmentArgonne National Laboratory • Cr 25% • Al 3% • Zr 0.1% • Y 0.1% • Fe < 1% • Ni Bal MTI presentation

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. MTI presentation

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 MTI presentation

Detection of Hydrogen in Titanium 4/1/2014 MTI presentation 32

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 4/1/2014 MTI presentation 33

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. 4/1/2014 MTI presentation 34

Casting Quality Prediction . Leak M35 -1 Casting 4/1/2014 MTI presentation 35

Niyama Values in Region of Leak Nymin = 0.58 Nymin = 0.69 ID OD mid-plane mid-plane Niyama values are in units of (°C-s)1/2/mm 4/1/2014 MTI presentation 36

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 4/1/2014 MTI presentation 37

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. 4/1/2014 MTI presentation 38

Corrosion Research at the Materials Technology Institute