Carbon and Alloy Steel
Metallurgy and
Processing

“The team I work with at Heysham 1, an Advanced Gas Reactor nuclear power station, is a reactive group. We respond to failures and breakdowns. The variety of work is huge and varies on a daily basis.

“The reactor’s been running now for 42 years and the original designs are even older.  If we need a spare part, the original material specs can be out of date or obsolete. So, a manufacturer will recommend a different material for a new part and we will then check whether the material properties are similar or better than the original and remain suitable for the application.

“I carry out a lot of the quality control inspections on spares arriving at site and these have material certificates with them, including chemical and mechanical analysis. Unsurprisingly, we have a high level of quality assurance. Throughout this process, having some background metallurgy knowledge is favourable.

“We also have a wide range of system temperatures here – from cryogenic liquid nitrogen and carbon dioxide at -196°C to superheated steam at 550°C. Different steels – and some stainless steels – are used to contain the various process mediums, and they all have different properties depending on the system’s contents and temperature.

“I felt I had a lack of background knowledge of metallurgy and wanted to fill that gap. It was important to gain a basic knowledge of carbon and alloy steels for my role at Heysham 1. I’d previously attended IMechE’s Metallurgy for Non-Metallurgists and found it really useful. So, when it came to looking for a more in-depth course, it was an easy choice to return to the IMechE. I didn’t look anywhere else. I felt the combination of the two courses would give me a good general understanding of metallurgy, without the need to specialise in material science.”

“The previous course I took, Metallurgy for Non-Metallurgists, was run Dr Philip Harrison and he delivered this one-day course, too. Phil’s delivery style is great; he gets all attendees involved. He has been in the metallurgy game for a long time, and is always able to give real-life examples, which bring greater context to the topics and issues covered.

“At the beginning, all the delegates explained what we wanted to get out this course, our roles and our previous experience. Phil is open to discussing any metallurgy issues an attendee has experienced in their own work and give his opinion, even if it’s not precisely in the course spec.

“We started off with the basics of metallurgy and crystal structure, before moving on to finer detail such as alloying elements and what effects they have. It’s a really good course that covers so much, from different types of steels and alloy steels to everything in between, such as testing, failures and failure mechanisms.

“If there’s anything you don’t understand or that needs further explanation, Phil has made the course flexible enough to accommodate that. For example, I wanted to find out more about fatigue and creep. Most of our machinery is rotating – we’ve got gas circulators spinning at 3000rpm. Fatigue is a massive issue with any rotating plant in any industry. And as we are working with high temperatures, we’re on the boundary of creep and creep failures. I’d never fully got to grips with creep but this course really helped my understanding of it and I now feel more confident.”

1 “Carbon and alloy steels are a huge proportion of any mechanical engineer’s work. To have some background knowledge of the topic will pay dividends in the future.”

2 “You’ll learn about the different effects of alloy elements on material properties – for example, when you are on the boundary of creep. It really helped me to understand the role creep plays in fatigue.”

3  “The course goes into detail on grain structure – why you’d want a certain grain structure and what effect that has on the material and its properties. When I see really high-resolution images of grain structure, I now have a good understanding of what we’re actually looking at. It’s fascinating.”

“As mechanical engineers, metal is our bread and butter. I’ve not done a material science degree, so I’m no metallurgist and there are times when I do have to go to the expert metallurgists. But taking this course has given me the confidence to now judge whether a material will be suitable for its intended use or application.

“Previously, I was regularly going to our fleet metallurgists with most problems. I am now more confident to say whether I am happy with a supplier’s suggestion or whether to accept a non-conformance due to using a modern equivalent material is OK on some of the more minor applications.

“We occasionally receive metallurgical forensic reports as part of investigations into a component’s failure. Being able to interpret that information is key. With the training I have received, my understanding of the content of the reports has been greatly improved.

“Of course, there are times when I still go to the metallurgists. I’ve always got that backing. But if I think back to how often I used to go to the metallurgists compared to now, there is definitely a quantifiable ROI. The cost of the entire course is probably a few hours of a metallurgist’s time, so we’ve absolutely paid off the investment.

“I keep the course notes in one of my drawers and I often find myself referring to them; just recently, for example, to check on the nickel content we need for a low temperature piece of kit and whether the proposed material is suitable for the application. It’s a good course, suitable for design engineers to aid in the selection of materials for components and for maintenance engineers to help with the resolution of defects and investigations.”

1 “Some basic understanding of metallurgy prior to attending this course will really help. Depending on your existing knowledge, consider taking Metallurgy for Non-Metallurgists or Fundamentals of Metallurgy. They will give an oversight of the building blocks of metallurgy, atomic structure and so on.”

2 “Bring some examples of issues you have faced, such as where something has broken for an unknown reason. Even if the course doesn’t precisely relate to that issue, Phil is more than happy to help out and try to give you the answer.”

3 “Carry on learning! Over time, the learning overlaps and all your knowledge merges together to make a whole.”

“I’m investing my time developing my skills and knowledge through further learning. For example, I’m taking a master’s degree in Advanced Mechanical Engineering at Lancaster University at the moment and I recently completed the IMechE’s Stainless Steel Metallurgy course. I’m also in the process of upgrading my membership to Incorporated through the IMechE.

“It’s an exciting time to be a Mechanical Engineer in the energy sector. There’s a lot of change, with new projects on the horizon to combat climate change and to supply renewable energy. Who knows where the future will take me?”