Download Corrosion Management I

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
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.
Just Flying along, enjoying the
ride....
what's so cool is they actually pay me to do this!
Hmmm. Strange sound.
Something feels different.
Hey, why am I looking up.??
Whoa here, what the hell?
Controls aren't working
Time for a mirror check.
Hey, where's the rest of my F-15.?
Uh oh, it's over there.
I think I've got a definite "Aw,
sh*t" going here...
I gotta wonder, am I the first guy
to ever experience
" cockpit-airframe separation
anxiety".
I'm outta here.
But first the canopy has to go.
Hey GREAT! That worked as
advertised. Things are looking
up!
OK, now it's my turn to go. I'm
gone - soon as I find the
eject handle.
Oh yeah, that's what I'm
talking about. Looks like it's
going to be just another
"average day at the office."
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.
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
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
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)
Determining and Organizing
Learning Outcomes
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•
•
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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
Stakeholder Input:
Historical Learning Outcomes
NACE – Dr. LaQue
Knowledge of …
Capability / Ability to …
• Corrosion basics (principles and mechanisms)
• Prevent corrosion
• Materials characteristics
• Diagnose failures
• Corrosive media
• Guide maintenance and repair
• Mechanical/physical properties
• Conduct inspections using relevant codes
• Testing and evaluation
• Set-up specifications and standards
• Fabrication and processing
• Work effectively on teams
• “Cost-effectiveness”, planning, execution
• Communicate effectively
Benefits : Increased Profitability
Stakeholder Input:
Federal Government
DoD – Dan Dunmire and Others
Knowledge of …
Capability / Ability to …
•
Inspection/detection
•
Prevention
•
Diagnostics and assessments
•
Assessment
•
Prognostics/prediction
•
Prediction
•
Mitigation Technologies
•
Management
•
Maintenance/repair
•
Materials selection, Optimal design
Benefits : Enhanced readiness
Cost Reduction
Improved Safety
Stakeholder Input:
Chemical Industry
Chemical Processing Industry
Knowledge of …
Capability / Ability to …
•
Corrosion basics
•
Make proper materials selection
•
Materials
•
Conduct diagnostic, failure assessments
•
Testing and evaluation
•
Conduct risk assessments
•
Mechanical properties
•
Organize risk-based inspections
•
Processing environment
•
Fabrication
•
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Assess/evaluate test results
Ensure Quality Control
•
Standards and specifications
•
Guide maintenance and rehabilitation
Benefits : Asset Preservation
Safety, Environmental Records Improvement
Stakeholder Input:
Other Industries
National Academies Assessment of Corrosion Education Highlighted Concerns from Industry Panels
Nuclear
Life-cycle prediction and life extension
Medical/Biomaterials
Materials reliability and component
integrity
Electronics
Materials performance
Reliability / system integrity
Oil and Gas
Safety
Materials reliability
Infrastructure
Safety (DOT)
Materials integrity (Water Distribution)
Transportation Systems
(Automotive/Aeronautics)
Cost effectiveness, reliability and
component integrity
Corrosion Education - Academic
Corrosion and Corrosion Control
Uhlig (MIT)
•
Definition/Importance/Forms
•
Atmospheric Corrosion
•
Electrochemistry
•
Corrosion in Water Systems
•
Thermodynamics/electrode potential
•
Oxidation/High Temperature Corrosion
•
Kinetics/rates/polarization
•
Cathodic & Anodic Protections
•
Passivity
•
Coatings (Metallic, Organic, Inorganic)
•
Effect of Stress: SCC, HC, Fatigue
•
Inhibitors/passivators
•
Galvanic Corrosion
•
Iron and Steel
•
Corrosion in soils
•
Non-Ferrous Metals and Alloys
Corrosion Education - Academic
Corrosion Engineering
Fontana & Greene (OSU)
•
Definition/Importance/Forms
•
Materials Selection
•
Principles of electrochemistry
•
Corrosion Prevention: Design
•
Principles of metallurgy
•
Corrosion Prevention: Coatings
•
Principles of environmental effects
•
Corrosion Prevention: Cathodic/Anodic
Protection
•
Corrosion Testing
•
Corrosion Prevention: Inhibitors
•
Metals and Alloys
•
Effect of the environment/chemistry
•
Non-metallics
•
Engineering Applications
•
Ceramics
•
High Temperature Oxidation
Corrosion Education - Academic
Theory of Corrosion & Protection of Metals
Tomashov (Russia)
• Introduction: Science of Corrosion
• Passivity
• Thermodynamics
• Galvanic Corrosion
• Kinetics
• Atmospheric Corrosion
• Metallic Films
• Underground Corrosion
• Electrode Potentials
• Seawater Corrosion
• Polarization
• Corrosion Resistant Metals & Alloys
Corrosion Education - Academic
Elementary Aspects of Corrosion / Corrosion of Metals
Neufeld (UK) / Shrier (UK)
• Principles of Corrosion & Oxidation
• Corrosion Cells
• Electrochemistry
• Principles of Metal Protection
• Polymers Chemistry
• Electrodeposition / Metallic Coatings
• Metals and Alloys
• Organic Coatings
• Non-Metallic Materials
• Corrosion Testing
• Corrosion Processes
• Design & Corrosion
Corrosion Training – Professional Societies
Corrosion: Understanding the Basics
ASM and NACE
• Introduction to corrosion
• Ferrous Alloys
• Basic concepts
• Non-ferrous alloys
• Thermodynamics
• Non-metallics
• Kinetics
• Corrosive environments
• Forms of Corrosion
• Failure Analysis
Testing and Monitoring
• Economics
• Electrochemical Test Methods
• Corrosion Control
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
First Half of Final Program
Second Half of Final Program
Corrosion-Centered Curriculum
• Key Corrosion Courses
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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
Corrosion-Centered Curriculum
Fundamentals of Aqueous Corrosion
Forms of Corrosion
Metals and Alloys
Thermodynamics
Effects of Stress
Kinetics
Flow/Velocity
Electrochemistry
Inhibitors
Passivity
Coatings
Text: Corrosion and Corrosion Control (Uhlig)
Corrosion-Centered Curriculum
Aqueous Corrosion Prevention
Metallic Materials Selection
Corrosion in Specific Industries
Non-Metallic Materials Selection
Metallurgical Factors
Coatings Selection
Polymer Materials
Inhibitors Selection
Engineering Considerations
Cathodic / Anodic Protection
Failure Analysis
Texts: Corrosion Engineering (Fontana & Greene)
Principles and Prevention of Corrosion (Jones)
Corrosion-Centered Curriculum
Fundamentals of Dry Corrosion
Thermodynamics
Bulk Materials (Metals and Ceramics)
Kinetics
Phase Diagrams (TTT Curves)
Mass Transfer Limitations
Diffusion and De-alloying
Chemical Environment Effects
Surface/Interface Effects
Forms of Hi-Temp Corrosion
Thermal cycle fatigue
Text: High Temperature Corrosion (Kofstad)
Corrosion-Centered Curriculum
Dry Corrosion Prevention
Failure Analysis
Physical and Chemical Analysis
Metallic Materials Selection
Alloying and heat treating
Non-Metallic Materials Selection
Solid state diffusion
Coating selection and formation
Interfacial stress
Degradation in Specific Industries
Aggressive Atmosphere
Text: High Temperature Corrosion (Kofstad)
Corrosion-Centered Curriculum
• Corrosion Labs
– Electrochemical Test Methods
– Chemical-Environmental Effects
– Chemical Reaction Rates
– Mass Transfer Limitations
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Failure Analysis/Sample preparation
Failure Analysis/Optical Microscopy
Failure Analysis/Electron Microscopy
Evaluate Stability/Corrosion Tendency
Evaluate Coatings
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)
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)
Corrosion-Centered Curriculum
• Proposed “Corrosion-Focused” Elective Courses
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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
Corrosion-Centered Curriculum
• Proposed “Corrosion-Focused” Elective Courses
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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
Science, Math and Engineering
• 15 Science and Math Courses
– Calculus through Differential Equations
– Chemistry through Analytical Chemistry
– Physics
• Additional Engineering Courses
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Chemical Engineering (2)
Mechanical Engineering (1)
Civil Engineering (2)
Electrical Engineering (1)
• 4 Project Management Experiences
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
Summary
Basic “Engineering Core” (Math & Sci.) Courses
15
Key “Corrosion” Courses
12
Other Engineering Courses
9
Engineering Elective Courses
4
General Education Courses
Total Undergraduate Courses
10
50
Total Undergraduate Credit Hours 136
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
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)
CLOSURE
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Feed-Back: Corrosion Curriculum
Assistance: Corrosion Lab Equipment
Participation: Co-op / Internships
Support: Student Scholarships
Sponsor: Faculty Positions
Engage: Teaching Electives / Focus areas