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Corrosion Prevention Compliance for Defense Acquisition Requirements

Course No. 324

(Course Outline shown below.)

For Whom Intended Government acquisition personnel, project managers, program managers, engineers, scientists, aides and technicians. Previous knowledge of corrosion or materials engineering is not required.

Objectives This course is designed to lead to a better understanding of US Government initiatives to prevent corrosion in Department of Defense equipment and infrastructure. The course's secondary goal is to provide basic understanding of the mechanisms of corrosion, and measures that can be used to control corrosion.

Brief Course Description Corrosion is responsible for the failure of many systems and structures. Unchecked corrosion can result in excessive maintenance and repair as well as system downtime and product contamination.

In December 2003, the US Department of Defense produced a report to Congress entitled, "Long-Term Strategy to Reduce Corrosion and the Effects of Corrosion on the Military Equipment and Infrastructure." This report called upon Congress to mandate and fund corrosion-prevention measures, in order to reduce the costs of dealing with corrosion after it occurs, and improve the defense readiness of the United States. This course will first focus on the impact of corrosion on laws and policies. US DoD plans, guidebooks and directives will be discussed as they relate to corrosion prevention and control planning, also to maintenance requirements and procedures.

Next, the course will review basic corrosion theory, including corrosion mechanisms and forms, before touching on design solutions based on corrosion type, fabrication method or environment. The science of characterizing corrosion is covered next, followed by material selection and testing. The instructor takes a detailed look at anti-corrosion coatings and finishes, and concludes with a summary of newer non-metallic, composite and other advanced materials.

Certificate Programs This course is an elective for any TTi specialist certificate program.

Prerequisites There are no definite prerequisites. No prior technical expertise is assumed.

Related Courses See also Course 320, Corrosion Control Techniques.

Text Each student will receive a course workbook, including most of the viewgraphs used in the course presentation.

Course Hours, Certificate and CEUs Open courses meet seven hours per day. Upcoming presentation dates can be found on our current open course schedule. Class hours/days for on-site courses can vary from 14-35 hours over 2-5 days as requested by our clients. Upon successful course completion, each participant receives a certificate of completion and one Continuing Education Unit (CEU) for every ten class hours.

Course Outline No. 324

Introduction: Impact of Corrosion, Laws, Policies and Guidance
- Potential Impact Of Corrosion
  - Cost · Readiness · Manpower · Safety · Quality Of Life
- Congressional Mandate For Corrosion Control
- DOD Corrosion Guidance
  - Corrosion Prevention and Mitigation Strategic Plan
  - Corrosion Prevention and Control Guidebook
  - Defense Acquisition Guidebook
  - DOD Directive 5200.1
  - DOD Instruction 5200.1
  - Additional Corrosion Control Guidance
- Corrosion Prevention And Control Organization
  - Corrosion Control Planning in the Defense Acquisition Process
  - Integration of Corrosion Control
  - Corrosion Prevention and Control Planning
- Maintenance Practices and Procedures
  - Need for Defining Required Maintenance During Design and Acquisition
  - Need for Documenting Maintenance Requirements and Procedures
  - Validating Maintenance Requirements and Procedures
  - Service Testing
  - Simulated Service Testing
  - Accelerated Testing
  - Balancing Initial System Costs and Maintenance Costs
Design-Related Corrosion Issues
- Basic Corrosion Theory
  - Definition of Corrosion
  - Driving Force For Corrosion of Metals
  - The Electrochemical Cell
- Forms of Corrosion
  - Immunity
  - General Corrosion
  - Galvanic Corrosion
  - Pitting
  - Concentration Cell Corrosion
  - De-alloying
  - Inter-granular corrosion
  - Stress corrosion cracking
  - Hydrogen embrittlement
  - Corrosion Fatigue
  - Flow-Assisted corrosion
  - Fretting corrosion
  - Stray current corrosion
Methods for Corrosion Control
- Materials selection
  - Materials selection methodologies
  - Information resources
- Protective coatings
  - Capabilities
  - Types
  - Coating Selection
  - Surface Preparation
  - Coating Inspection
- Change of environment
Design Solutions Based on Corrosion Type
Design Solutions Based on Fabrication Techniques
- Impact of Welding
- Impact of Welding
- Impact of Heat Treatment
- Impact of Cold Work
- Impact of Surface Finish
Design Solutions Based On Environmental Considerations
- Effect of Temperature on Corrosion
- Free Drainage
- Atmospheric Environment Factors
- Fresh Water Immersion
- Salt Water Immersion
- Splash and Spray Exposure
Critical Corrosion Design and Materials Tradeoffs
- Designing to Accept Corrosion of Selected Materials
- Selecting Materials to Resist Environment and Design
Corrosion Testing and Characterization of Materials
- Natural Environment Testing
- Simulated Service Testing
- Accelerated Corrosion Testing
Analysis and Correction of Corrosion Problems
- Identification of Corrosion Problems
- Visual Observations
- Non-Destructive Testing
- Destructive Evaluations
- Correction of Corrosion Problems
- Modification of Design
- Change of Materials
- Modification of Environment
- Application of Corrosion Control Measures
Coatings, Sealants, Adhesives, Finishes, Inhibitors and Their Impact on Corrosion
- Coatings
  - Purpose
  - Types of Corrosion that can be Effectively Mitigated by Coatings
  - Improper Use of Coatings
- Sealants and Adhesives
  - Purpose
  - Types of Corrosion that Can be Effectively Mitigated by Sealants and Adhesives
  - Improper Use of Sealants and Adhesives
- Finishes
  - Effect of Finish on Corrosion
  - Selection and Specifications for Surface Finishes
- Corrosion Inhibitors
  - Types of Corrosion Inhibitors
    - Anodic Film Formers
    - Cathodic Film Formers
    - Surface Film Formers
  - Application of Corrosion Inhibitors
    - Batch Application
    - Continuous Application
  - Vapor Phase Inhibitors
  - Inhibitors in Coatings
Non-Metallic and Composite Materials
- Types Of Non-Metallic Materials
- Deterioration Mechanisms of Non-Metallic Materials
  - Absorption and Swelling
  - Oxidation
  - Ultraviolet Light
  - Continued Polymerization
  - Bulk versus Surface Effects
- Composite Materials
  - Effects on Matrix
  - Effects on Reinforcement
New Technology Materials
- Advances in Metallic Materials
- Advances in Non-Metallic Materials and Composites
- Advantages And Disadvantages of Using Advanced Materials
Summary and Conclusions
- Corrosion Is Natural, But Controllable
- Corrosion Control is Cost Effective
- Corrosion Affects Readiness, Safety and Other Vital Issues
- Corrosion Control Technology is Well Developed
- Consideration of Corrosion Control is a Requirement in the Acquisition Process
- Final exam
- Award of certificates for successful completion

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