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Corrosion Chronicles: Daily Summaries Delivered
by Materials Technology Institute
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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- 2 days ago1h 2m
SEM & EDS in Failure Analysis: Let the Sample Tell the Story
In this episode, failure analysis expert Tedd Anastas of Anastas Technical Services and Brent Moore of Moore Analytical join co-host Heather Allain and guest host Andrew Rentsch, Materials Engineer at Huntsman Corporation, for a practical discussion on scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and their role in failure analysis and materials investigations. The conversation explores how SEM differs from optical microscopy, how SEM paired with EDS can reveal important chemical and microstructural clues, and why EDS results are often best treated as qualitative indicators rather than precise quantitative measurements. Tedd and Brent discuss detection limits, normalized compositions, false positives, fatigue striations, fracture surface interpretation, contaminants, inclusions, non-metallic materials, sputter coating, and elemental mapping. Along the way, they share case study examples, practical investigation tips, and a few unexpected detours involving dinosaur eggs and wig hair. This episode is sponsored by Tricor Metals and Rolled Alloys. Corrosion Chronicles is produced by Association Briefings.
- May 6, 20261h 5m
Providing Materials Expertise to Process Commercialization
In this episode, Richard Clapp, retired principal consultant from DuPont, joins co-hosts Heather Allain and Marc Cook for a discussion on the role of materials expertise in process commercialization. Drawing on decades of industry experience, Richard outlines the three primary types of process commercialization and the institutional challenges companies often face when scaling new processes from the bench to production. The conversation explores how impurities, feedstock variability, and solids handling can introduce unexpected complications, as well as why engineers tend to take conservative approaches to materials recommendations during commercialization efforts. Richard also breaks down common “show stoppers” and explains the importance of the three C’s—corrosion, compatibility, and clean-up—when evaluating process systems. Additional topics include corrosion testing at both bench and pilot scale, the subtle but important differences that can exist between seemingly identical plants, considerations when using toll manufacturers for pilot operations, and practical advice for organizations navigating process commercialization projects. This episode is sponsored by Tricor Metals and Rolled Alloys. Corrosion Chronicles is produced by Association Briefings.
- Apr 1, 202642 min
Hydrofluoric Acid and Anhydrous Hydrogen Fluoride - Part 2
In this episode, the second installment of a two-part series, Bert Jennings, owner of Jennings Materials Consulting in Spring, Texas, rejoins co-hosts Heather Allain and Marc Cook to continue their discussion on hydrofluoric acid (HF) and anhydrous hydrogen fluoride (AHF) service. Building on Part 1, the conversation shifts to detection, materials, and real-world application. Bert outlines key NDE techniques for identifying cracking and hydrogen blistering, then dives into weld practices and the importance of proper stress relief in carbon steel systems. The group also explores alternative materials, including austenitic stainless steels, ceramics, and glass, along with a “learn from failures” story that highlights the consequences of small oversights. The episode wraps with insights on nickel alloys, welding challenges, and the role of FRP and fluoroplastics—reinforcing that success in HF service depends on both material selection and execution. This episode is sponsored by Tricor Metals and Rolled Alloys. Show Notes Related reference for MTI members: MS-4 Materials Selector for Hazardous Chemicals: Hydrogen Fluoride and Hydrofluoric Acid Non-members: Visit the MTI bookstore. Corrosion Chronicles is produced by Association Briefings.
- Mar 4, 202642 min
Hydrofluoric Acid and Anhydrous Hydrogen Fluoride - Part 1
In this episode, the first installment of a two-part series, Bert Jennings, owner of Jennings Materials Consulting in Spring, Texas, joins co-hosts Heather Allain and Marc Cook for a technical discussion on hydrofluoric acid (HF) and anhydrous hydrogen fluoride (AHF) service. Bert begins by outlining where HF is commonly used and addressing common industry tropes and misconceptions about how the fluid behaves in process environments. He explains what “anhydrous” truly means in practical terms, including how dry anhydrous hydrogen fluoride must be and why strict moisture control is essential. The conversation dives into the unique hazards associated with HF, particularly in carbon steel systems. Bert discusses hydrogen blistering, hydrogen-assisted stress corrosion cracking (HASCC), and the influence of hardness on material performance. He also examines how residual elements in carbon steel can affect corrosion resistance and cracking susceptibility, highlighting why small compositional differences can lead to significant performance impacts in HF service. The episode concludes with practical considerations for materials selection, inspection, and risk mitigation, setting the stage for deeper exploration in Part 2 of the series. This episode is sponsored by Tricor Metals and Webco Industries. Show Notes Related reference for MTI members: MS-4 Materials Selector for Hazardous Chemicals: Hydrogen Fluoride and Hydrofluoric Acid Non-members: Visit the MTI bookstore. Corrosion Chronicles is produced by Association Briefings.
- Feb 4, 202654 min
Corrosion and Wear Materials Solutions
In this episode, Robert Freed, Ph.D., FASM, Associate Director at the Materials Technology Institute, joins co-hosts Heather Allain and Marc Cook for a practical, materials-focused discussion on corrosion and wear. Robert helps clarify the differences between abrasion, adhesive wear, erosion, and cavitation, and explains how these damage mechanisms commonly show up in industrial equipment such as extruders and other high-wear components. The conversation explores key variables that influence wear performance, how wear can accelerate corrosion, and why factors like particle size matter. Robert also walks through methods for evaluating and ranking materials, including relevant ASTM wear tests, metals lab analysis, and the pros and cons of different overlay solutions—such as laser cladding, thermal spray, and weld overlay—as well as non-metallic options. The episode closes with insight into MTI-led research projects and practical considerations for selecting materials and processes to manage wear in demanding operating environments. This episode is sponsored by Tricor Metals and Webco Industries. Corrosion Chronicles is produced by Association Briefings.
- Jan 7, 202654 min
Eddy Current Testing (ECT) of Heat Exchanger Tubes
In this episode, Evan Lowrance, Corporate NDT Engineer at Webco Industries, and Jonathan Konerza, Tubing Division Manager at Sentinel Integrity Solutions, join co-hosts Heather Allain and Marc Cook for an in-depth look at eddy current testing (ECT) of heat exchanger tubes. Together, they break down how ECT works, the differences between internal and external testing, and how factors like magnetism and material conductivity influence test results. The conversation explores how eddy current testing compares to IRIS testing, what types of defects ECT is best suited to detect, and where its limitations exist. Evan and Jonathan also discuss the importance of reference standards, technician qualification, and tailoring inspection programs to expected degradation mechanisms. The episode wraps with practical insight into evaluating NDE providers and recognizing warning signs that testing may not be delivering reliable results. This episode is sponsored by Tricor Metals and Webco Industries. Corrosion Chronicles is produced by Association Briefings.
- Dec 3, 20251h 1m
Column Internals
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.
- Nov 5, 202552 min
Explosion Cladding
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.
About Corrosion Chronicles
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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