An original podcast series from the Materials Technology Institute, focused on materials in the processing industry and the experts within the community.
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In this episode, Danny Mock, managing partner for M10 Process Equipment, Inc., joins co-hosts Heather Allain and Marc Cook to take listeners inside the world of column internals and the fundamentals that drive mass-transfer performance. Danny breaks down what mass-transfer equipment is and how internals efficiency is evaluated, offering practical insight into design considerations that influence reliability and long-term operation. He discusses the importance of selecting materials with appropriate corrosion allowances, how internals are attached and supported, and what engineers should know about bolted fasteners, dissimilar metals, tray flatness, and the risks associated with creep and thermal expansion. The conversation also covers column fires, static charge generation, and the role of random packing in modern column design. Whether you're troubleshooting existing towers or designing new equipment, this episode provides a comprehensive look at the details that matter most inside a process column.
This episode is sponsored by Tricor Metals and Webco Industries.
Corrosion Chronicles is produced by Association Briefings.
Explosion Cladding (00:52:53)
In this episode, Mukesh Ahlavadi, Global Director of the Chemicals Market at NobelClad, joins co-hosts Heather Allain and Marc Cook to explore the world of metal cladding and its critical role in modern engineering applications. Together, they provide an overview of hot roll bonding versus explosion cladding, examining the key drivers behind each process and why industries turn to cladding for enhanced material performance and corrosion resistance. Mukesh walks through essential fabrication considerations, including the use of batten strips, interlayers, and post-cladding operations, while sharing insights into heat treatment, forming clad plate, and lessons learned from a 1990s clad failure. Listeners will gain a clear understanding of how explosion cladding was discovered, the mechanics of the process, and how the distinctive wave pattern at the clad interface reflects quality and bonding integrity.
This episode is sponsored by Tricor Metals and Webco Industries.
Corrosion Chronicles is produced by Association Briefings.
Gasketed Joints (01:00:44)
In this episode, Kevin Ganschow, materials & corrosion consultant at Mechanical Materials Engineering, LLC, joins co-hosts Heather Allain and Marc Cook to unpack the intricacies of gasketed joints. The discussion begins with a foundational look at flange assemblies as systems before diving into key factors such as gasket stress, bolt reuse, and lubrication. Kevin highlights best practices for bolted joint assembly and integrity programs, emphasizing the importance of assembler training, flange tagging, and condition assessment. The episode also explores advanced considerations including joint relaxation, hot tightening, hot bolting, and bolt relaxation, offering practical insights for engineers and operators aiming to enhance reliability and safety in their systems.
This episode is sponsored by Tricor Metals and Webco Industries.
Corrosion Chronicles is produced by Association Briefings.
How a Materials Lab Works (00:54:15)
In this episode, Jennifer Larimore and Avery Boyer, Materials Engineers at Chemours, join co-hosts Heather Allain and Marc Cook to share an inside look at how a materials lab works. Jennifer and Avery walk through the step-by-step process of analyzing samples—from sectioning, cleaning, reviewing documentation and photographing through the final wrap up of documenting and communicating findings to the customer. They discuss analysis methods like nondestructive evaluation, XRF identification, hardness, fracture testing, polishing and metallography to uncover critical material properties. The discussion also explores the importance of turning technical findings into clear, actionable recommendations. Throughout the conversation, the guests highlight how these practices help solve real-world challenges, prevent failures, and ensure long-term reliability.
This episode is sponsored by Tricor Metals and Webco Industries.
Corrosion Chronicles is produced by Association Briefings.
Materials Selection During Project Execution (00:37:49)
In this episode, Cathleen Shargay, Advisor of Materials and Welding Engineering at Becht, joins co-hosts Heather Allain and Marc Cook to explore the complexities of materials selection during project execution. The conversation covers a wide range of essential topics, from understanding what materials selection diagrams (MSDs) are and how they interface with process engineering, to evaluating life cycle cost inputs and establishing design life. Cathleen also unpacks how MSDs relate to Integrity Operating Windows (IOWs) and Corrosion Control Documents (CCDs), and how these tools work together to support informed decision-making. The episode dives into strategies for managing excursions, assessing corrosion circuits, and understanding the consequences of material failure. Finally, the discussion looks ahead to how artificial intelligence is beginning to shape materials selection and analysis in the future of engineering.
This episode is sponsored by Tricor Metals and Webco Industries.
Corrosion Chronicles is produced by Association Briefings.
High Temperature Hydrogen Attack (00:39:36)
In this episode, Nate Sutton, materials engineer at Equity Engineering, joins co-hosts Heather Allain and Marc Cook for a deep dive into high-temperature hydrogen attack (HTHA) and the evolving guidance used to evaluate and mitigate its risks. Nate shares his firsthand insights on the origins and evolution of Nelson curves, the role of post-weld heat treatment, and the recent development of time-dependent curves still under review by API. The discussion also explores the role of advanced non-destructive examination (NDE) techniques, MTI’s contributions to HTHA detection and assessment, and how fitness-for-service decisions are made under high-stakes conditions.
This episode is sponsored by Tricor Metals and Webco Industries.
Corrosion Chronicles is produced by Association Briefings.
NDE of In-service Equipment (00:55:46)
In this episode, Ana Benz, Chief Engineer at IRISNDT, joins co-hosts Heather Allain and Marc Cook for a deep dive into selecting non-destructive examination (NDE) techniques based on expected damage mechanisms. Ana shares insights on recent advancements in radiography, field-based hardness testing, and imaging of hardness indents to assess effectiveness. The conversation also explores proper surface cleaning for inspections, the use of chemical composition analysis to detect degradation from galvanic corrosion, and the role of Integrity Operating Windows (IOWs). Additional topics include remote monitoring applications and innovations in remote inspection technology.
Corrosion Chronicles is produced by Association Briefings.
Abrasion and Erosion (00:56:37)
In this episode, Murray Pearson, Director, HPM Technology Development, Metals at Hatch, joins hosts Heather Allain and Marc Cook to delve into the intricacies of abrasion, erosion, and erosion corrosion. They explore the impact of these phenomena on various equipment types, the materials responsible for these damages, and effective strategies for equipment protection. Topics include impingement effects, methods for evaluating material suitability such as plant coupon testing, ongoing MTI research initiatives, factors influencing abrasion rates, and advanced NDE techniques for equipment assessment.
Corrosion Chronicles is produced by Association Briefings.
Fabrication Considerations for Duplex Stainless Steels (00:46:26)
In this episode, Ben Sprengard, managing director of innovation at Enerfab, sits down with co-hosts Heather Allain and Marc Cook to discuss fabrication considerations for duplex stainless steels. They explore key topics, including property comparisons to austenitic stainless steels, forming, machining, welding, phase transformation during cooling, welding QC, solution annealing, QC for duplex fabrication, in-service inspection, and heat exchanger specifics.
Corrosion Chronicles is produced by Association Briefings.
Mining and mineral processing (00:50:30)
In this episode, Steven Clarke joins co-hosts Heather Allain and Marc Cook to dive into the world of mining and mineral processing. They break down the differences between hydrometallurgy and pyrometallurgy, explore various leaching methods, and discuss solvent extraction and electrowinning. The conversation highlights how water and ore contaminants impact material compatibility, the challenges of abrasion resistance, and what new materials the mining industry could benefit from.
Corrosion Chronicles is produced by Association Briefings.
Failure Analysis and Incident Response (00:46:07)
In this episode, Gary Whittaker, retired Engineering Fellow from Eastman Chemical and MTI Fellow, sits down with co-hosts Heather Allain and Marc Cook to recount some past failures he was involved in failure analysis on. They chat about: an API storage tank that leaked and contaminated a nearby river, some Nickel-Chrome-Moly alloy piping with stress cracking found due to indications on an associated clad vessel, and some Nickel-Moly alloy piping with stress cracking.
Corrosion Chronicles is produced by Association Briefings.
Creep (00:57:18)
In this episode, Arun Sreeranganathan, principal at Stress Engineering Services, sits down with co-hosts Heather Allain and Marc Cook to discuss creep in the context of chemical facilities. They chat about: the definition of creep, homologous temperature, creep in plastics, contrasting creep with SRC, How the ASME code handles the subject, creep curves, sources for creep info, how creep data is developed, using uniaxial data to design for multiaxiality in equipment, and methods for determining remaining life from creep.
Corrosion Chronicles is produced by Association Briefings.
Corrosion Testing (00:55:47)
In this episode, Ben McCurry, Senior Expert of Materials Engineering and Inspection at BASF Corporation, joins co-hosts Heather Allain and Marc Cook to dive into the world of corrosion testing. They cover a wide range of topics, including the purpose of corrosion testing, lab testing versus in-situ methods, and the use of corrosion resistance tables. The discussion explores valuable insights from sister plants, decision-making criteria for conducting tests, and the design of coupons. They also tackle advanced topics like high-pressure/high-temperature data, the effects of aeration and agitation, post-exposure examination, grinding on coupons, field coupon accessibility, and how process conditions impact field testing results.
Corrosion Chronicles is produced by Association Briefings.
Stress Relaxation Cracking (00:43:49)
In this episode, Jan-willem Rensman, Fellow at Fluor and subject matter expert in Metallurgy and Welding, joins co-hosts Heather Allain and Marc Cook for an in-depth discussion on stress relaxation cracking (SRC). Together, they cover topics including: defining SRC and understanding where and when it occurs, the differences between SRC and creep, managing residual stresses in welds, and offering design and fabrication strategies to prevent SRC. The conversation also touches on shop versus field weld considerations, selecting appropriate welding techniques, SRC guidelines in design codes, recommended resources for design standards, and methods for SRC detection and repair.
Corrosion Chronicles is produced by Association Briefings.
Show notes
References which contain guidelines for SRC mitigation:
API TR 942-B (2017). Materials, Fabrication, and Repair Considerations for Austenitic Alloys Subject to Embrittlement and Cracking in High Temperature 565°C to 760°C (1050°F to 1400°F) Refinery Services, American Petroleum Institute, Washington, DC.
Fahrion, M. E., Brown, J. C., Hassell, J. C., & Birke, A. (2003, March). Technical basis for improved reliability of 347H stainless steel heavy wall piping in hydrogen service. In NACE CORROSION (pp. NACE-03647). NACE.
Penso, J., & Shargay, C. (2021, July). Stress Relaxation Cracking of Thick-Wall Stainless Steel Piping in Various Refining Units. In Pressure Vessels and Piping Conference (Vol. 85345, p. V004T06A044). American Society of Mechanical Engineers.
Rensman, J. W., Spindler, M. W., & Shargay, C. (2023, July). Stress Relaxation Cracking, A Misunderstood Problem in the Process Industry. In Pressure Vessels and Piping Conference (Vol. 87486, p. V005T06A060). American Society of Mechanical Engineers.
Stress Corrosion Cracking (00:41:06)
In this episode, Dale McIntyre, a designated professional with the Materials Technology Institute, joins co-hosts Heather Allain and Marc Cook to dive into the topic of anodic stress corrosion cracking, with a specific focus on chloride stress corrosion cracking (CSCC). They explore key SCC degradation mechanisms and discuss crucial factors in assessing CSCC risks. The conversation covers a range of topics, including reducing surface stress to minimize risk, temperature thresholds for CSCC, crack initiation timelines, NDE methods, the use of duplex stainless steel, insulation, painting, CSCC repair, and the role of castings in managing corrosion.
Corrosion Chronicles is produced by Association Briefings.
Show notes
Members: Environmental Cracking
Public: Order Environmental Cracking
Flexible Hoses (00:50:40)
In this episode, Steve Springer, a materials engineer at Chemours Engineering, joins co-hosts Heather Allain and Marc Cook to discuss the critical role of flexible hoses in chemical facilities. They cover a range of topics, including a tragic incident that resulted in a fatality, the importance of having a robust hose program, and key considerations in hose design and construction. The conversation also touches on appropriate and inappropriate uses, corrosion allowance, inspection protocols, full penetration welds for end connections, pressure and vacuum ratings, and best practices for installation.
Corrosion Chronicles is produced by Association Briefings.
Show notes
To download the Reliability Guidelines for Flexible Hoses book:
Members: https://access.mti-global.org/record/571?ln=en&v=pdf
Nonmembers: https://www.mti-global.org/participate/public-library/flexible-hose-reliability-guide
Storm Damage Preparation and Assessment (00:36:52)
In our season 2 premier, Ed Naylor, Senior Materials Engineering Associate at Nouryon, sits down with co-hosts Heather Allain and Marc Cook to discuss storm damage in the context of chemical facilities. They explore how to identify site-specific vulnerabilities, the unique hazards hurricanes pose, and essential preparation steps before storm season. The discussion also covers the role of hazard response teams, the cascading effects of storm damage, post-storm assessments, and the material degradation mechanisms to anticipate.
Show notes
Ed would like to include his thanks to his colleagues Frank Upton, Rodney Ward and Chris Waddell.
Damage Assessment: Investigating Chemical Plant Fires, Explosions and Storm Damage book: https://www.mti-global.org/participate/public-library/investigating-chemical-plant-fires-explosions-storms
Ed Naylor is a Senior Materials Engineering Associate with Nouryon, formerly AkzoNobel.
He has a Bachelors of Science in Chemical Engineering from Cornell University and a Masters of Science in Metallurgical Engineering from The Ohio State University.
For over 35 years, he has been involved in all aspects of materials technology, inspection, corrosion engineering, failure analysis, mechanical integrity, process safety management and maintenance networking. He holds API certifications for Pressure Vessel, Piping, Aboveground Storage Tank and Fixed Equipment source inspection.
He represents Nouryon’s interests in several societies including AMPP, PIP, ASTM and the Materials Technology Institute [MTI]. He has served MTI as TAC Chair, Board Chair and a Director for over 20 years. In 2022, he received his highest professional honor when designated as an MTI Fellow. Ed enjoys fishing, cooking and spending time with his wife Jennifer. They have 2 grown sons.
Corrosion Chronicles is produced by Association Briefings.
Benefits and Challenges of Tantalum (00:48:10)
In our season 1 finale, host Heather Allain flips the script by interviewing her co-host, Marc Cook, for an in-depth discussion on tantalum. They explore the various alloys of tantalum, its market dynamics, pricing trends, and the types of equipment where tantalum is used. Tune in to learn about hydrogen embrittlement, fabrication basics, inspection and testing methods, and repair techniques.
Corrosion Chronicles is produced by Association Briefings.
Benefits and Challenges of Titanium and Zirconium (00:45:51)
In this episode, Richard Sutherlin, a metallurgical and corrosion consultant, sits down with co-hosts Heather Allain and Marc Cook to discuss titanium and zirconium alloys. They chat about the unique properties of specific grades of titanium, their various applications, and the challenges of identifying and assessing hydriding in titanium tubes. They also discuss safety considerations and proper procedures when working with pyrophoric materials like zirconium and titanium.
Corrosion Chronicles is produced by Association Briefings.
Show notes
Best Practices for Reactive & Refractory Metals Five Volume Set Available for Purchase (mti-global.org) (public)
Best Practices for Reactive and Refractory Metals (mti-global.org) (member)
Benefits and Challenges of Plastic Lined Pipe (00:40:41)
In this episode, David Yanik, Product Engineering Manager at Crane ChemPharma, sits down with co-hosts Heather Allain and Marc Cook to discuss plastic-lined pipe. They chat about liner manufacturing methods, permeation, liner flaring, factory versus field flaring, predicting remaining life, gaskets, retorque, torque values, Belleville washers and damage mechanisms.
Corrosion Chronicles is produced by Association Briefings.
Benefits and Challenges of Corrosion Resistant Masonry Lined Systems (00:43:55)
In this episode, Kevin Brooks, president of Knight Material Technologies, sits down with co-hosts Heather Allain and Marc Cook to discuss corrosion testing for linings. Tune in as they explore various topics including inspection methods for linings, the use of thermal imaging for inspections, core sampling techniques, equipment cleaning procedures, safe methods for equipment storage, equipment size ranges, chemical expansion of bricks, and considerations for thermal shock and external insulation.
Corrosion Chronicles is produced by Association Briefings.
Benefits and Challenges of Stainless Steels (00:39:19)
In this episode, Gary Coates from the Nickel Institute sits down with co-hosts Heather Allain and Marc Cook to discuss stainless steels. The three chat about: the various series of stainless steel; magnetism as an identification technique; changes in stainless compositions as a function of time; stress corrosion cracking; sustainability in the context of stainless steel; PREN number; material suitability evaluation; temperature limits; and passivation.
Benefits and Challenges of Fiber-Reinforced Composites (00:48:08)
In this episode, industry veteran Dale Keeler, Associate Director at MTI, sits down with co-hosts Heather Allain and Marc Cook to discuss fiber-reinforced composites (FRP). The three chat about: fabrication methods; the types of fiber, resin and additives; differences in design standards and practices around the globe; how material properties used in design are determined and validated; inspection and life assessment techniques; flange design; and thermal shock.
Show notes
Public bookstore – Guide for Repair and Alteration of FRP Equipment:
https://marketplace.mimeo.com/mtiglobal/product/e3fb7e600fb4423b9532394fd8e7ec7b
Members bookstore – Guide for Repair and Alteration of FRP Equipment:
https://marketplace.mimeo.com/mtiglobalMEMBERS/product/1868c1a40bd94e05be701ab394d89498
Embedded RFID Sensor Technology
https://www.mti-global.org/rfid-microsite/monitor-frp-vessel-integrity-with-rfid-sensors
Risk Based Inspection for FRP Tanks
https://access.mti-global.org/record/562?ln=en
Global FRP Standards Comparative Report
https://access.mti-global.org/record/337?ln=en
Accelerated Testing of FRP
https://access.mti-global.org/record/78?ln=en
Corrosion Chronicles is hosted by Heather Allain and Marc Cook.
Heather Allain is the Executive Director of Materials Technology Institute (MTI). She has been with the organization for 16 years and previously held an Associate Director position facilitating MTI’s Project work. Before MTI, she worked as a Materials Engineer at DuPont for 15 years, and has a BS in Materials Engineering from Rice University.
Marc Cook has a BS in Chemical Engineering from Purdue University and an MS in Material Engineering from NC State. He has worked for Dow for 26 years and at a contracting company in Cincinnati for 3 years. His current role at Dow is leading the Technical Services Team for Ceramics and Refractory at Dow and providing materials engineering support to Dow’s Freeport, Texas site.
Disclaimer: Marc Cook is an employee of Dow but is speaking purely in a personal capacity and is not talking about or recommending Dow products.
Corrosion Chronicles is produced by Association Briefings.
Benefits and Challenges of Ceramic Refractories (00:53:01)
In this episode, Jay Schickling, senior principal consultant at Chemours, sits down with co-hosts Heather Allain and Marc Cook to discuss refractory ceramics. The three chat about refractory linings details for process heaters, including: bricks, monolithic linings, ceramic fiber, thermal expansion, dryout, anchoring systems, inspection techniques, acceptance criteria for defects, and repair techniques.
Show notes
For more information about MTI’s Global Solutions Symposium, visit https://www.mti-global.org/mtisymposium/home
Additional MTI resources:
On-demand ceramics trainings: https://www.mti-global.org/participate/education
Corrosion Chronicles is hosted by Heather Allain and Marc Cook.
Heather Allain is the Executive Director of Materials Technology Institute (MTI). She has been with the organization for 16 years and previously held an Associate Director position facilitating MTI’s Project work. Before MTI, she worked as a Materials Engineer at DuPont for 15 years, and has a BS in Materials Engineering from Rice University.
Marc Cook has a BS in Chemical Engineering from Purdue University and an MS in Material Engineering from NC State. He has worked for Dow for 26 years and at a contracting company in Cincinnati for 3 years. His current role at Dow is leading the Technical Services Team for Ceramics and Refractory at Dow and providing materials engineering support to Dow’s Freeport, Texas site.
Disclaimer: Marc Cook is an employee of Dow but is speaking purely in a personal capacity and is not talking about or recommending Dow products.
Corrosion Chronicles is produced by Association Briefings.
Benefits and Challenges of Polymer-lined Steel Vessels (00:53:52)
In this episode, industry veterans Debra Mc Cauley and Dale Heffner sit down with co-hosts Heather Allain and Marc Cook to discuss polymer-lined steel vessels. The four chat about the end user drivers when purchasing polymer-lined steel vessels, including overall uses and costs; the supply chain and how the resins are produced; advantages and disadvantages of steel-lined equipment compared with dual laminate equipment; the use of cap strips; design details that need to be managed for the polymer-lined steel; hot water and helium tests and integrity techniques; and managing permeation in plastics.
Show notes
For more information about MTI’s Global Solutions Symposium, visit https://www.mti-global.org/mtisymposium/home
Additional MTI resources:
Cap Strip Video
The lined equipment document is only available to members in the e-Library
Public bookstore – Guide for Repair and Alteration of FRP Equipment
Members bookstore – Guide for Repair and Alteration of FRP Equipment
Dual Laminate Podcast
Corrosion Chronicles is produced by Association Briefings.
