Blogs

Metal Dusting – Case Histories, New Processes with Risks, and Gaps in Knowledge

By MTI Admin posted 7 days ago
TRACK: Materials for Harsh Environments Metal dusting is a damage mechanism that occurs under very specific process conditions, so it is not widespread, but when it occurs it is often at catastrophic rates. Also, although extensive past literature has been published providing laboratory test data, each data set is specific to a set of conditions and they are not easily compared with one another. Often the resistant alloys vary based on the test conditions. This paper builds on past papers by compiling case histories, listing numerous past published literature with test programs, and detailing the current inadequate methods (and subtle caveats) for predicting ...

Quit Being So Sensitive – An Investigation of Sensitization Behavior of Alloy 600 During Welding

By MTI Admin posted 8 days ago
TRACK: Failures/Failure Analysis Sensitization is a known phenomenon that occurs in Alloy 600 in operating temperature ranges of 1000°F to 1800°F due to the precipitation of chromium carbides (Cr7C3 and Cr23C6). The resultant grain-boundary precipitation of these chromium carbides can result in increased susceptibility to intergranular attack when exposed to corrosive media. In this study, the effects of material characteristics (carbon content) and weld processing parameters (heat input, maximum interpass temperature) on Alloy 600’s microstructure and corrosion resistance via ASTM G28A are investigated. Additionally, mitigation techniques (lab-performed post-weld ...

Embedded RFID Sensors for FRP Corrosion Barrier Monitoring - Update on Implementation in Chemical Process Applications

By MTI Admin posted 13 days ago
TRACK: Nonmetallics FRP vessel integrity monitoring with MTI RFID sensors continues to advance. Sensor arrays have been installed in 11+ new FRP vessels to support plant equipment integrity programs. Practical application and observations will be discussed based on experience to date. Topics will include pre-installation testing, sensor naming conventions, sensors in secondary bonds, sensor in primary corrosion barriers, fabrication techniques and challenges, sensor interrogation, post-curing and material additives. This presentation will build on the update provided at the 2024 Global Symposium. MTI Global Solutions Symposium 2026 ...

Using Life Cycle Cost Analysis to Differentiate Materials of Construction Choices

By MTI Admin posted 15 days ago
TRACK: Safety/Reliability Life cycle cost analysis is widely regarded as a useful tool when comparing material of construction alternatives for new equipment. Despite that, it can be hard to find specific guidance on everything that should be included and how to determine some of the inputs for comparing CPI equipment options. The goal of this talk is to provide a complete step-by-step tutorial on how to conduct this assessment, with discussion points to provide clarification as needed. Examples of topics that are covered in depth are how to determine a failure frequency and how to account for the lost production margin from unplanned downtime within the analysis, ...

Experiences and Learnings from a Phosgene Hose Failure

By MTI Admin posted 19 days ago
TRACK: Failures/Failure Analysis A fatality occurred at an operating facility when an unloading hose on a phosgene ton cylinder failed unexpectedly. This presentation will highlight the physical causes of the failure, but will also reveal the weaknesses in the mechanical integrity program that was in effect at the time. As is common with all engineering applications, the complexities of the materials selection, design, application, and use of this particular hose will be discussed. The attendee will be provided insights and encouragement to establish a site hose management program, and be given a look into the life lessons learned by the presenter. ...

Case Study on Reliability of Modern Materials: Fluoropolymer Lined Engineered Structural Composite Piping Systems

By MTI Admin posted 27 days ago
TRACK: Safety/Reliability Maintaining a competitive advantage in emerging and growth markets like minerals, desalination, data centers, semiconductors, specialty chemicals, chlor-alkali, and steel requires plant operators and engineering firms to be educated on modern materials. Corrosive environments demand advanced piping materials to cut lifecycle costs and boost uptime. New piping solutions face hurdles such as lack of testing standards, limited awareness, and knowledge gaps among engineers, especially those focused only on metallic systems. Fluoropolymer-lined engineered structural composite piping will be used as a case study to illustrate how these ...

Mechanical Integrity of High Temperature Steam Methane Reformer Furnace Tubes

By MTI Admin posted 29 days ago
TRACK: Materials for Harsh Environments As the primary source for bulk hydrogen production worldwide, steam methane reformers (SMRs) require heat resistant materials to withstand their challenging continuous operating conditions that exceed 815°C. Good high temperature creep performance is a requirement for materials used in such conditions and HP-modified, HP-microalloyed grades of Ni-based alloys are commercially employed for such applications. However, prolonged exposure to high temperatures promotes changes to the metastable microstructure of these alloys and an understanding of the effects of such transformations on long-term creep performance of these ...

Long-term metal dustings experiments and ASME Code Case for New Alloy N06699

By MTI Admin posted 12-18-2025
TRACK: Emerging Technologies The newly developed Ni-based alloy N06699 has been designed for high-temperature applications in the chemical and petrochemical industry, exhibiting an excellent resistance under metal dusting conditions due to the high Cr (approx. 30 wt.%) and Al (approx. 2 wt.%) content and the reduced Fe content (< 2.5 wt.%). The corrosion performance in these aggressive conditions has been proven in several metal dusting experiments, not only for the base material (plate and bar) but also for welded and printed samples from powder via PBF-LB/M. Recently, long-term experiments with a duration of up to 10,000 h verified again the outstanding ...

Rubber Lining in Harsh Chemical Environments: Modern Strategies for Long-Term Reliability and Field Application Challenges

By MTI Admin posted 12-17-2025
TRACK: Non-Metallics Rubber lining remains one of the most proven solutions for corrosion resistance in chemical processing environments, yet its effectiveness hinges on much more than material selection. This presentation will explore the critical success factors of rubber lining systems—from substrate preparation and atmospheric curing techniques to material handling and field installation practices—particularly for tanks, piping, and complex geometries in high-risk service conditions. Drawing from field-proven case studies, this session will examine challenges encountered with large-diameter tanks and vessels that cannot be autoclave-cured, and where ...

Graphitic Corrosion of Cast Iron Piping: A Background and Practical Approach to Identification in Underground Installations

By MTI Admin posted 12-17-2025
TRACK: Failure/Failure Analysis Cast iron pipes are often laid underground and forgotten because, usually, nothing happens to them for decades. Over the past few years, several sections of cast and ductile iron pipe have been sent to my lab for failure analysis having all met the same fate: Graphitic corrosion caused by acidic soil (usually associated with salt for melting ice on roads and walkways) after ~40 years of service. This presentation offers a background into graphitic corrosion of cast and ductile iron pipes, including metallographic samples from field failures, and a discussion on the problems it has caused. A practical approach to identifying ...

Anhydrous Ammonia - Storage Tank Inspection and Stress Corrosion Cracking Experience

By MTI Admin posted 12-17-2025
TRACK: Materials for Harsh Environments Anhydrous ammonia is typically stored in carbon steel tanks, for both pressurized systems in ASME Code vessels and refrigerated systems at atmospheric pressure in API-design flat bottom tanks. Storage tank inspection experiences for both types of systems will be shared. The basics of ammonia stress corrosion cracking in as-welded steels will be presented, along with inspection techniques for evaluating and determining the integrity of storage vessels that are subject to, or have been, stress corrosion cracked. MTI Global Solutions Symposium 2026 February 23-26 Charlotte, NC See ...

Keeping Up with Change: An Overview of Recent ASME BPVC Revision

By MTI Admin posted 12-17-2025
TRACK: Emerging Technology The ASME Boiler and Pressure Vessel Code (BPVC) establishes the benchmark for the safe design and construction of boilers and pressure vessels. Revised on a biennial basis, the Code evolves to reflect advancements in technology and the latest available data. While some updates have minimal impact, others—though subtle—can create significant ripple effects throughout the industry. It is essential for professionals engaged with the ASME BPVC to stay informed about recent code revisions, understand the rationale behind these changes, and assess their implications for their organization’s operations. Join us to hear: - A brief history ...

Understanding Reaction Forces in Hinged and Gimbal Expansion Joints

By MTI Admin posted 11-24-2025
TRACK: Safety/Reliability Industry standards like ASME B31.3 for Process Piping and NEMA SM23 for mechanical equipment establish guidelines for stress limits and allowable nozzle loads to ensure system reliability. Expansion joints play a vital role in piping systems by absorbing thermal expansion and reducing mechanical stress, providing necessary pipe flexibility and ensuring compliance with these limits. Without them, process piping and equipment such as steam turbines and turbo-expanders could be exposed to excessive forces, leading to irreversible damage and premature failure. Metallic expansion joints are designed according to the Expansion Joint Manufacturers ...

Graphite Heat Exchangers: A Lifecycle and Material Overview from the End-User Perspective

By MTI Admin posted 11-24-2025
TRACK: Non-Metallics The presentation will cover end-user experience with graphite heat exchangers from different angles including design, fabrication, inspection, installation, maintenance, process monitoring/control, failure modes and repairs. There are multiple designs of graphite heat exchangers, but in this presentation, the main focus will be on shell-and-tube and cylindrical block heat exchangers. At the beginning, the presentation starts with a quick dive into the facts about graphite material and how it is produced for chemically corrosive service. Is graphite material exactly the same across the major graphite manufacturers? The presentation will ...

In Memory of Galen Hodge, MTI Fellow

By MTI Admin posted 10-22-2025
ST. LOUIS, MO. – It is with heavy hearts that we share the passing of Galen Hodge, longtime member and MTI Fellow. Hodge had over 23 years of dedicated service to MTI as the Designated Representative for Haynes International. In 1980, he joined the Board of Directors and served diligently on the Finance, Audit and Membership Committees before moving into a leadership role as the Vice-Chairman and Board Chairman from 1993 to 1996. He left the board in 1999 and retired as the Designated Representative of Haynes in 2001 but continued to serve MTI as an Associate Director. We greatly appreciate all the work Galen put in as the head of the organization and behind ...

The Crucial Roles of Materials and Corrosion Engineers in Achieving Sustainable Development Goals

By MTI Admin posted 10-07-2025
Introduction The United Nations’ 17 Sustainable Development Goals (SDGs) serve as a global roadmap for achieving sustainable progress, addressing issues from poverty reduction and equality promotion to building sustainable cities and improving climate resilience, both in Denmark and globally. These goals are interconnected, emphasizing that meaningful progress requires tackling economic, social, and environmental challenges together. Materials engineers are key contributors to achieving the SDGs by driving innovation, advancing sustainability, and ensuring reliability in materials and processes. Their expertise in designing, testing, and producing materials ...

Evaluation of New Glass Lining Repair Technique

By MTI Admin posted 09-09-2025
Introduction Glass-lined steel (GLS) offers benefits such as excellent corrosion resistance to a broad range of chemicals, product purity, a non-stick surface, and lower purchasing costs compared to nickel alloy or reactive metals. Unlike thermoplastic-lined options, the glass lining will not permeate and can handle full vacuum. However, glass is susceptible to mechanical damage, has limited allowable bolt load and gasket types for its flange connections, and any lining damage can only be covered, not truly repaired. Due to the breadth of its chemical resistance, GLS can shine in reactor applications where the chemistry can vary greatly during its residence ...

Development of a CUI Estimation Model Based on Actual CUI Inspection Data

By MTI Admin posted 08-12-2025
Abstract Corrosion under insulation (CUI) is a common and safety-critical type of corrosion in aged chemical plants. Currently, CUI inspections are mainly carried out by setting up scaffolding and removing the thermal insulation because there is no efficient and cost-effective nondestructive inspection method for CUI. The cost is enormous, and in many cases, corrosion may not be present even after the insulation is removed for inspection. Therefore, it is important to properly estimate the areas to be inspected. Several CUI estimation methods have been proposed, but the accuracy is not sufficiently high. CUI inspections have been conducted for many years, on ...

MTI 2026 Symposium Keynote on Cutting-Edge Accident Investigation Technologies

By MTI Admin posted 07-17-2025
Charlotte, NC – February 23, 2026 – The Materials Technology Institute (MTI) is proud to announce that Erik M. Mueller of the National Transportation Safety Board (NTSB) will deliver the keynote presentation at MTI’s 2026 Symposium, which takes place February 23–26, 2026, in Charlotte, North Carolina. Mueller, a leading expert from the NTSB’s Materials Laboratory Division in Washington, DC with 18 years' experience, will present “Using Novel Technologies to Perform Accident Investigations: Benefits and Challenges in Future NTSB Materials Laboratory Investigations.” His keynote will explore how the NTSB has enhanced traditional fracture analysis with advanced ...

Evaluation and Prevention of HAZ Grain Boundary Liquation Cracking in Alloy 800H Forgings

By MTI Admin posted 07-09-2025
BY: BENJAMIN A. SPRENGARD, PE, MSC, CWI, ASNT III ENERFAB PROCESS SOLUTIONS Executive Summary Alloy 800H is a high-performance, nickel-iron-chromium alloy that is specifically designed for high-temperature service. Its composition and properties make it suitable for a range of demanding applications, including pressure vessels, heat exchangers, and other process components. However, 800H has an inherent susceptibility to solidification cracking during fabrication due to its larger grain structure and alloying additions. In this case study, Alloy 800H (UNS N08810) forgings were welded with NiCr-3 filler metal. Microfissures were observed with dye penetrant ...