David E. Hendrix, P.E.

Metallurgical engineering involves the study of corrosion mechanisms within industrial metals and alloys and their electrochemical, physical and mechanical properties.

The ability to select appropriate metals, alloys, nonmetallic materials, linings and coatings for specific applications is integral to solving many corrosion-related problems and failures. Such material selection for chemical processes and new design applications has long-term ramifications in both economic longevity and safety considerations.

Example areas that a senior metallurgical engineer deals with include recommending and specifying:

  • heat-resistant and carburization-resistant furnace tubes for reforming and ethylene pyrolysis heaters
  • highly-alloyed steels for hydrocarbon fuel and municipal waste combustion gas environments
  • stainless steels and nickel alloys to resist aggressive aqueous, acidic and alkaline aqueous processing
  • environments, downhole alloys, and coatings for oil drilling and production applications
  • the use of copper and galvanized steel for potable water systems
  • pump impeller alloys for brine service and powder metallurgy alloys for pelletizer blades
The senior metallurgical engineer also has experience in applying, evaluating and specifying metallic coatings for metal and alloy substrates including thermal-spray, galvanized, aluminized, electroless nickel, chromium plating and other finishing operations. He/she develops specifications for clients for fabricating, welding, repairing and procuring equipment and pressure vessels, testing and inspecting fabricated and welded components and equipment. Important contributions are also made in ground-water remediation design projects.

The metallurgical engineering discipline involves testing and inspection of metallic underground and aboveground storage tanks. Corrosion is the main cause of leaking underground storage tanks, which release a variety of liquid fuels and solvents to the subsurface and ground water. Sampling for chemical analyses are required in many cases to evaluate conditions. Corrosion of water supply systems (pumps, piping and water well casing) is involved in other types of ground-water contamination. Metallurgical failure analyses and associated corrosion control procedures often play a part in remediation as well as in pump failures for water supply systems.

Forensic studies are needed under some circumstances when the cause of an explosion or accident is under investigation.

Note: The environmental field is multidisciplinary by nature, and ELA incorporates input from complimentary disciplines for maximum effectiveness whenever appropriate.