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