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Corrosion Engineering: Addressing a National Problem

Learn about the Corrosion Engineering B.S. Degree Program at the University of Akron, a comprehensive curriculum designed to combat corrosion issues impacting national infrastructure and economy.

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Corrosion Engineering: Addressing a National Problem

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  1. Corrosion Education Initiative U.Akron/Corrosion Engineering B.S. Degree Program • Background • Corrosion Engineering Curriculum • Progress to-date Goal: - Discussion of the program • Collect feedback Aziz Asphahani

  2. Background First discussion 3 years ago (summer 06) Based on Corrosion Cost/Preventive Strategies Report Devastating Impact on Economy ($276 Billion in 2002) Retiring Work Force (5-10 years) Federal Government Interest (Regulatory Push) Public Safety/Infrastructure Congressional activities (H.R.1770 & H.R.6234) DOT regulations (FHWA) Department of Justice criminal negligence Corrosion Cost to DOD (>$15 Billion/yr.) DOD Office of Corrosion Policy and Oversight DOD Instruction 5000.1 To date DOD has appropriated funds to our initiative at a level of $ 1.9 million.

  3. Just Flying  along, enjoying the ride.... what's so cool is they actually pay  me to do this! 

  4. Hmmm. Strange sound.   Something feels  different. 

  5. Hey, why am I looking up.??

  6. Whoa here, what the hell?  Controls aren't working

  7. Time for a mirror check.  Hey, where's the  rest of my F-15.?

  8. Uh oh, it's  over there.  I think I've got a definite "Aw, sh*t" going here...

  9. I gotta wonder, am I the first guy to ever  experience " cockpit-airframe separation anxiety".

  10. I'm outta here. But  first the canopy has to go.

  11. Hey GREAT!   That worked as advertised.  Things are looking up!

  12. OK, now it's my turn to go.  I'm gone - soon as I  find the eject handle.

  13. Oh yeah, that's what I'm talking about.   Looks like it's going to be just another "average day at the office."  

  14. What caused the mid air break up?  • The connection at the fuselage behind the cockpit failed due to corrosion. • This incident caused the USAF to ground the entire F-15 Strike Eagle fleet.

  15. Demand (2007) - Employment survey/Eduventures - 650 Companies responded to online survey - New Hire Demand: (1300 open positions in Corrosion related jobs) - NACE membership survey - 2403 responses / 8196 contacts - 44% active Corrosionists to retire in next 10 years

  16. University of Akron’s Initiative • National Outreach --Addressing a significant national problem • Synergy within the College of Engineering --Existing, successful engineering degrees • Supporting Science & Engineering --Promoting interest/careers in Engineering

  17. B.S. in Corrosion Engineering • Based on input from stakeholders (learning outcomes) • Consistent with existing programs • Comprehensive “Corrosion Engineering” Degree - Maintains: Strong “Engineering Core” - Ensures : “Corrosion-Centered” Curriculum - Includes : “Corrosion Management” Components • Could be started within an existing program (Draws upon existing courses)

  18. Determining and Organizing Learning Outcomes • Collected/organized input from key stakeholders • Developed course sequence • Reviewed course sequence with several stakeholders • Added recommended details to courses • Incorporated Management Sequence & Co-op sessions

  19. Stakeholder Input: Historical Learning Outcomes NACE – Dr. LaQue Benefits : Increased Profitability

  20. Stakeholder Input:Federal Government DoD – Dan Dunmire and Others Benefits : Enhanced readiness Cost Reduction Improved Safety

  21. Stakeholder Input:Chemical Industry Chemical Processing Industry Benefits : Asset Preservation Safety, Environmental Records Improvement

  22. Stakeholder Input:Other Industries National Academies Assessment of Corrosion Education - Highlighted Concerns from Industry Panels

  23. Corrosion Education - Academic

  24. Corrosion Education - Academic

  25. Corrosion Education - Academic

  26. Corrosion Education - Academic

  27. Corrosion Training – Professional Societies

  28. Learning Outcomes Content Organization • Foundation: Strong “Engineering Core” • Focus: “Corrosion-Centered” courses - Fundamental Knowledge: Corrosion Science - Applied Knowledge: Corrosion Engineering - Skill-Based: Apprenticeship Model - Management Tools: Economics • Repeated exposure to content • Project management

  29. First Half of Final Program

  30. Second Half of Final Program

  31. Corrosion-Centered Curriculum • Key Corrosion Courses • Tools for Corrosion Engineering • Fundamentals of Aqueous Corrosion* • Aqueous Corrosion Prevention* • Fundamentals of Dry Corrosion* • Dry Corrosion Prevention* • Corrosion Management I • Corrosion Management II * Taught in parallel with 1 credit hour lab

  32. Corrosion-Centered Curriculum Fundamentals of Aqueous Corrosion Text: Corrosion and Corrosion Control (Uhlig) • Forms of Corrosion • Thermodynamics • Kinetics • Electrochemistry • Passivity • Metals and Alloys • Effects of Stress • Flow/Velocity • Inhibitors • Coatings

  33. Corrosion-Centered Curriculum Aqueous Corrosion Prevention Texts: Corrosion Engineering (Fontana & Greene) Principles and Prevention of Corrosion (Jones) • Metallic Materials Selection • Non-Metallic Materials Selection • Coatings Selection • Inhibitors Selection • Cathodic / Anodic Protection • Corrosion in Specific Industries • Metallurgical Factors • Polymer Materials • Engineering Considerations • Failure Analysis

  34. Corrosion-Centered Curriculum Fundamentals of Dry Corrosion Text: High Temperature Corrosion (Kofstad) • Thermodynamics • Kinetics • Mass Transfer Limitations • Chemical Environment Effects • Forms of Hi-Temp Corrosion • Bulk Materials (Metals and Ceramics) • Phase Diagrams (TTT Curves) • Diffusion and De-alloying • Surface/Interface Effects • Thermal cycle fatigue

  35. Corrosion-Centered Curriculum Dry Corrosion Prevention Text: High Temperature Corrosion (Kofstad) • Failure Analysis • Metallic Materials Selection • Non-Metallic Materials Selection • Coating selection and formation • Degradation in Specific Industries • Physical and Chemical Analysis • Alloying and heat treating • Solid state diffusion • Interfacial stress • Aggressive Atmosphere

  36. Corrosion-Centered Curriculum • Corrosion Labs • Electrochemical Test Methods • Chemical-Environmental Effects • Chemical Reaction Rates • Mass Transfer Limitations • Failure Analysis/Sample preparation • Failure Analysis/Optical Microscopy • Failure Analysis/Electron Microscopy • Evaluate Stability/Corrosion Tendency • Evaluate Coatings

  37. Corrosion-Centered Curriculum • Corrosion Management I • Diagnostic (Testing/Monitoring) • Standards • Prognostic (Assessment/Prediction) • Economics / Life-extension • Inspection/Detection • Protocol • Mitigation • Safety • Repair, Rehabilitation and Maintenance • Cost-effectiveness Texts: Engineering Design (Dieter)

  38. Corrosion-Centered Curriculum • Corrosion Management II • Life-cycle Costing - Fitness for Service • Policy • Safety • Optimal Design • Localized Level • System Level • Specifications and Standards • Policies • Strategies for cost reduction Text: Engineering Design (Dieter)

  39. Corrosion-Centered Curriculum • Proposed “Corrosion-Focused” Elective Courses • Cathodic and Anodic Protections • Metallic Coatings / Electroplating • Organic Coatings / Polymers • Bio-Materials • Smart Materials • Microbiologically Induced Corrosion (MIC) • Safety, Health and Corrosion • Environmental Sustainability and Corrosion

  40. Corrosion-Centered Curriculum • Proposed “Corrosion-Focused” Elective Courses • Physicochemical Mechanics of Fracture • Failure Modes & Effects Analysis (FMEA) • Reliability / Systems Integrity • Nano-Sensors • Risk-Based Inspection • Infrastructure/Bridges life-extension • Pipelines Integrity • Refinery & Petro-chemical Processes

  41. Science, Math and Engineering • 15 Science and Math Courses • Calculus through Differential Equations • Chemistry through Analytical Chemistry • Physics • Additional Engineering Courses • Chemical Engineering (2) • Mechanical Engineering (1) • Civil Engineering (2) • Electrical Engineering (1) • 4 Project Management Experiences

  42. Project Management Sequences -- Project Management and Teamwork • Apprentice Model • Skills Development -- Co-Op assignments • Minimum three assignments • Typically with one company -- Capstone Design • System level engineering

  43. Summary

  44. Progress to-date • Curriculum has been approved by Chemical & Biomolecular Engineering Dept. • Curriculum has been approved in principle by Undergraduate Curriculum Committee • It is being reviewed at the College of Engineering level, before proceeding to a vote on the curriculum this semester

  45. Start Up: Faculty, Staff, Facilities • Faculty • 2 in year 1 • 1 in year 2 • 1 in year 3 • Staff • Lab technician • Co-op office support • Facilities • Adequate space for teaching, for research labs and administrative offices National Academies / ROCSE Committee (Research Opportunities in Corrosion Science & Engineering)

  46. CLOSURE • Feed-Back: Corrosion Curriculum • Assistance: Corrosion Lab Equipment • Participation: Co-op / Internships • Support: Student Scholarships • Sponsor: Faculty Positions • Engage: Teaching Electives / Focus areas

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