Corrosion and Reliability Engineering at The University of Akron September 12, 2015

Corrosion and Reliability Engineering at

The University of Akron

April 19, 2023

The Corrosion and Reliability Program benefits society, industry and government through enhanced corrosion control for reduced costs of corrosion and for greater performance, safety and reliability. This is accomplished through the development and implementation of education, training, research and service.

“Focus at the intersection of engineering, science and management for greater reliability, safety and reduced

costs of corrosion”April 19, 2023 Contact name and number

Applied RDT&E

Advanced Degrees(UA or other universities)

Degree ProgramsB.S. Corrosion Engineering

Corrosion Associate and Baccalaureate Engineering Technology Degrees

Certification and Licensure and

Non-Credit Workshops• Collaborative Agreement with NACE International

•Discussions with the Society for Protective Coatings (SSPC)

Innovative Products

Students/Graduates

Industry Partners

An Innovative and Holistic Approach to Filling the Education Gap

April 19, 2023 Contact name and number


• Curriculum Approval– Approved by the College of Engineering and UA Faculty

Senate – Spring 2009– Accepted by the UA Board of Trustees – June 2009– Pending approval by the Ohio Board of Regents

• Instructional Lab– Existing space being renovated to accommodate introductory lab courses– Scheduled for completion in December 2009– Funding provided by FY09 DoD contract

• Program Team and Faculty

Program UpdateProgram Update(Activities Since December 2008)(Activities Since December 2008)

Program UpdateProgram Update(Activities Since December 2008)(Activities Since December 2008)


Stakeholder Input: Stakeholder Input: Stakeholder Input: Stakeholder Input:

Knowledge of… Capability/ability to … Benefit

Corrosion basics (principles and mechanisms)

Materials characteristics

Corrosive media

Mechanical/physical properties

Testing, evaluation, inspection

Corrosion prevention

Fabrication and processing

“Cost-effectiveness”, planning, execution and management

Prevent corrosion

Diagnose failures

Guide maintenance and repair

Conduct inspections using relevant codes

Set-up specifications and standards

Life cycle costing

Risk based assessment

Manage projects

Work effectively on teams

Communicate effectively

Asset preservation

Increased profitability

Enhanced readiness

Improved safety

Lower environmental impact

DODNACE, MTIAcademia – MIT, OSU, UD, CWRU, IITNational Academies – Industrial panels

•Based on input from various stakeholders (learning outcomes)

•Consistent with existing programs

Comprehensive Corrosion Degree

Maintains engineering core

o Multi-disciplinary

Includes strong science and engineering foundation

•Adds management component

•Could be started within an existing program

Draws upon existing courses


B.S. in Corrosion EngineeringB.S. in Corrosion Engineering


•Fundamentals of Science and Math•Maintains engineering core•Builds upon existing College of Engineering courses•Ensures strong Corrosion Science foundation•Corrosion Prevention•Analysis of Corrosion

•Adds Corrosion Management components

•Modular approach for flexible delivery

Repeated exposure to content and project management

Corrosion-Centered ProgramCorrosion-Centered Program


• Multiple entry points to serve a diverse student population

• Realistic pathways for students to re-enter or continue the educational process with maximum efficiency and minimal cost

• Opportunities for industry to gain value from working with our students and hiring our graduates– Strong educational foundation at all levels– Blending of critical engineering and science fundamentals with practical

experience (strengths of the co-op model)– Students and graduates who can apply their education to “real world” projects

Bridge ApproachBridge Approach


Corrosion Centered CurriculumCorrosion Centered Curriculum

• Core Courses in CorrosionCore Courses in Corrosion– Tools for Corrosion EngineeringTools for Corrosion Engineering– Fundamentals of Aqueous Corrosion*Fundamentals of Aqueous Corrosion*– Aqueous Corrosion Prevention*Aqueous Corrosion Prevention*– Fundamentals of Dry Corrosion*Fundamentals of Dry Corrosion*– Dry Corrosion Prevention*Dry Corrosion Prevention*– Corrosion Management ICorrosion Management I– Corrosion Management IICorrosion Management II

* Taught in parallel with 1 credit hour lab* Taught in parallel with 1 credit hour lab

• Core Courses in CorrosionCore Courses in Corrosion– Tools for Corrosion EngineeringTools for Corrosion Engineering– Fundamentals of Aqueous Corrosion*Fundamentals of Aqueous Corrosion*– Aqueous Corrosion Prevention*Aqueous Corrosion Prevention*– Fundamentals of Dry Corrosion*Fundamentals of Dry Corrosion*– Dry Corrosion Prevention*Dry Corrosion Prevention*– Corrosion Management ICorrosion Management I– Corrosion Management IICorrosion Management II

* Taught in parallel with 1 credit hour lab* Taught in parallel with 1 credit hour lab



Fundamentals of Aqueous CorrosionFundamentals of Aqueous Corrosion

Text:Text: Elementary Corrosion and Corrosion Control (Uhlig)Elementary Corrosion and Corrosion Control (Uhlig)

Fundamentals of Aqueous CorrosionFundamentals of Aqueous Corrosion

Text:Text: Elementary Corrosion and Corrosion Control (Uhlig)Elementary Corrosion and Corrosion Control (Uhlig)

Electrochemistry Thermodynamics Kinetics

Chemical/Environment EffectsApplication to forms of corrosion

Bulk Materials Crystal Structure and Defects Microstructure Alloys

SurfacesStress/Strain and Fatigue



• Corrosion LabsCorrosion Labs

– Electrochemical Test MethodsElectrochemical Test Methods– Chemical-Environmental EffectsChemical-Environmental Effects

– Chemical Reaction RatesChemical Reaction Rates– Mass Transfer LimitationsMass Transfer Limitations

– Failure Analysis/Optical MicroscopyFailure Analysis/Optical Microscopy– Failure Analysis/Sample PreparationFailure Analysis/Sample Preparation– Failure Analysis/Electron MicroscopyFailure Analysis/Electron Microscopy– Evaluate Coatings/Stability/Corrosion TendencyEvaluate Coatings/Stability/Corrosion Tendency

• Corrosion LabsCorrosion Labs

– Electrochemical Test MethodsElectrochemical Test Methods– Chemical-Environmental EffectsChemical-Environmental Effects

– Chemical Reaction RatesChemical Reaction Rates– Mass Transfer LimitationsMass Transfer Limitations

– Failure Analysis/Optical MicroscopyFailure Analysis/Optical Microscopy– Failure Analysis/Sample PreparationFailure Analysis/Sample Preparation– Failure Analysis/Electron MicroscopyFailure Analysis/Electron Microscopy– Evaluate Coatings/Stability/Corrosion TendencyEvaluate Coatings/Stability/Corrosion Tendency


Project ManagementProject Management

Management SequenceManagement Sequence

– Project Management and TeamworkProject Management and Teamwork• Once per yearOnce per year• Apprentice ModelApprentice Model• Affective SkillsAffective Skills

– Co – Op assignmentsCo – Op assignments• At least three assignmentsAt least three assignments• Typically one companyTypically one company

– Capstone DesignCapstone Design• System level engineeringSystem level engineering

Management SequenceManagement Sequence

– Project Management and TeamworkProject Management and Teamwork• Once per yearOnce per year• Apprentice ModelApprentice Model• Affective SkillsAffective Skills

– Co – Op assignmentsCo – Op assignments• At least three assignmentsAt least three assignments• Typically one companyTypically one company

– Capstone DesignCapstone Design• System level engineeringSystem level engineering


Distance Learning at The University of AkronDistance Learning at The University of AkronDistance Learning at The University of AkronDistance Learning at The University of Akron

29 Distance Learning Classrooms

Multimedia and VideoconferencingCODEC for point-to-point and multi-point videoconferencing

Touch sensitive SmartBoard

Connected to hundreds of locations

BerlinLondonMadridMoscowTokyo



• Corrosion Management ICorrosion Management I

– Diagnostic (Testing/Monitoring) Diagnostic (Testing/Monitoring) • StandardsStandards

– Prognostic (Assessment/Prediction)Prognostic (Assessment/Prediction)• Effect on process and systemEffect on process and system

– Inspection/DetectionInspection/Detection• PolicyPolicy

– MitigationMitigation• Cost effectivenessCost effectiveness• SafetySafety• Repair, Rehabilitation and MaintenanceRepair, Rehabilitation and Maintenance• Equipment Life ExtensionEquipment Life Extension

Texts: Principles and Prevention of Corrosion (Jones)Texts: Principles and Prevention of Corrosion (Jones)Engineering Design (Dieter)Engineering Design (Dieter)

• Corrosion Management ICorrosion Management I

– Diagnostic (Testing/Monitoring) Diagnostic (Testing/Monitoring) • StandardsStandards

– Prognostic (Assessment/Prediction)Prognostic (Assessment/Prediction)• Effect on process and systemEffect on process and system

– Inspection/DetectionInspection/Detection• PolicyPolicy

– MitigationMitigation• Cost effectivenessCost effectiveness• SafetySafety• Repair, Rehabilitation and MaintenanceRepair, Rehabilitation and Maintenance• Equipment Life ExtensionEquipment Life Extension

Texts: Principles and Prevention of Corrosion (Jones)Texts: Principles and Prevention of Corrosion (Jones)Engineering Design (Dieter)Engineering Design (Dieter)

First Half of Final Program


Second Half of Final Program


Corrosion-Centered Curriculum


• Existing ElectivesExisting Electives

– Chemistry/Biology ElectiveChemistry/Biology Elective• 3100:1113100:111 Principles of Biology 1 (4)Principles of Biology 1 (4)• 3100:1123100:112 Principles of Biology 2 (4)Principles of Biology 2 (4)• 3150:4633150:463 Advanced Organic Chemistry (3)Advanced Organic Chemistry (3)• 3150:4723150:472 Advanced Inorganic Chemistry (3)Advanced Inorganic Chemistry (3)• 9871:4079871:407 Polymer Science (4)Polymer Science (4)

– Corrosion Engineering ElectivesCorrosion Engineering Electives– Electives Requiring No Additional Pre-requisite Courses Electives Requiring No Additional Pre-requisite Courses

• 4200:3304200:330 Chemical Reaction Engineering (3)Chemical Reaction Engineering (3)• 4200:3534200:353 Mass Transfer Operations (3)Mass Transfer Operations (3)• 4200:4084200:408 Polymer Engineering (3)Polymer Engineering (3)• 4200:4724200:472 Separation Processes in Biochemical Engineering (3)Separation Processes in Biochemical Engineering (3)• 4200:4964200:496 Topics in Chemical EngineeringTopics in Chemical Engineering• 4300:3064300:306 Theory of Structures (3)Theory of Structures (3)• 4600:2034600:203 Dynamics (3)Dynamics (3)• 4800:3604800:360 Biofluid Mechanics (3)Biofluid Mechanics (3)• 4800:4004800:400 Biomaterials (3)Biomaterials (3)

• Existing ElectivesExisting Electives

– Chemistry/Biology ElectiveChemistry/Biology Elective• 3100:1113100:111 Principles of Biology 1 (4)Principles of Biology 1 (4)• 3100:1123100:112 Principles of Biology 2 (4)Principles of Biology 2 (4)• 3150:4633150:463 Advanced Organic Chemistry (3)Advanced Organic Chemistry (3)• 3150:4723150:472 Advanced Inorganic Chemistry (3)Advanced Inorganic Chemistry (3)• 9871:4079871:407 Polymer Science (4)Polymer Science (4)

– Corrosion Engineering ElectivesCorrosion Engineering Electives– Electives Requiring No Additional Pre-requisite Courses Electives Requiring No Additional Pre-requisite Courses

• 4200:3304200:330 Chemical Reaction Engineering (3)Chemical Reaction Engineering (3)• 4200:3534200:353 Mass Transfer Operations (3)Mass Transfer Operations (3)• 4200:4084200:408 Polymer Engineering (3)Polymer Engineering (3)• 4200:4724200:472 Separation Processes in Biochemical Engineering (3)Separation Processes in Biochemical Engineering (3)• 4200:4964200:496 Topics in Chemical EngineeringTopics in Chemical Engineering• 4300:3064300:306 Theory of Structures (3)Theory of Structures (3)• 4600:2034600:203 Dynamics (3)Dynamics (3)• 4800:3604800:360 Biofluid Mechanics (3)Biofluid Mechanics (3)• 4800:4004800:400 Biomaterials (3)Biomaterials (3)

Corrosion-Centered Curriculum


– Electives Requiring Additional Pre-requisite Courses not in Corrosion Electives Requiring Additional Pre-requisite Courses not in Corrosion Engineering ProgramEngineering Program

• 3100:3313100:331 Microbiology (4 cr)Microbiology (4 cr)• 4200:4704200:470 Electrochemical EngineeringElectrochemical Engineering• 4300:4034300:403 Reinforced Concrete Design (3)Reinforced Concrete Design (3)• 4600:3364600:336 Analysis of Mechanical Components (3)Analysis of Mechanical Components (3)• 4800:4404800:440 Advanced Biomaterials (3)Advanced Biomaterials (3)

– DesignDesign• 4200:1944200:194 Chemical Engineering Design 1 (1 cr)Chemical Engineering Design 1 (1 cr)• 4200:2944200:294 Chemical Engineering Design 2 (1-2 cr)Chemical Engineering Design 2 (1-2 cr)• 4200:3944200:394 Chemical Engineering Design 3 (1-3 cr)Chemical Engineering Design 3 (1-3 cr)• 4200:4944200:494 Chemical Engineering Design 4 (3 cr)Chemical Engineering Design 4 (3 cr)• 4300:3414300:341 Hydraulic EngineeringHydraulic Engineering• 4300:4264300:426 Environmental Engineering Design (3 cr)Environmental Engineering Design (3 cr)• 4300:4804300:480 Reliability Based DesignReliability Based Design• 4600:4624600:462 Pressure Vessel Design (3) Pressure Vessel Design (3)

– Electives Requiring Additional Pre-requisite Courses not in Corrosion Electives Requiring Additional Pre-requisite Courses not in Corrosion Engineering ProgramEngineering Program

• 3100:3313100:331 Microbiology (4 cr)Microbiology (4 cr)• 4200:4704200:470 Electrochemical EngineeringElectrochemical Engineering• 4300:4034300:403 Reinforced Concrete Design (3)Reinforced Concrete Design (3)• 4600:3364600:336 Analysis of Mechanical Components (3)Analysis of Mechanical Components (3)• 4800:4404800:440 Advanced Biomaterials (3)Advanced Biomaterials (3)

– DesignDesign• 4200:1944200:194 Chemical Engineering Design 1 (1 cr)Chemical Engineering Design 1 (1 cr)• 4200:2944200:294 Chemical Engineering Design 2 (1-2 cr)Chemical Engineering Design 2 (1-2 cr)• 4200:3944200:394 Chemical Engineering Design 3 (1-3 cr)Chemical Engineering Design 3 (1-3 cr)• 4200:4944200:494 Chemical Engineering Design 4 (3 cr)Chemical Engineering Design 4 (3 cr)• 4300:3414300:341 Hydraulic EngineeringHydraulic Engineering• 4300:4264300:426 Environmental Engineering Design (3 cr)Environmental Engineering Design (3 cr)• 4300:4804300:480 Reliability Based DesignReliability Based Design• 4600:4624600:462 Pressure Vessel Design (3) Pressure Vessel Design (3)

Corrosion-Centered CurriculumProposed Elective Course Topics or Focus Areas

• Refining Processes

• Polymer Coatings

• Cathodic and Anodic Protection

• Electroplating

• Microbiologically Induced Corrosion (MIC)

• Environmental Sustainability and Corrosion

• Biomaterials/Nanosensors

• Safety, Health and Corrosion

• Systems Integration/Reliability

• Risk-Based Inspection

• Physicochemical Mechanics of Fracture

• Failure Modes and Effects Analysis (FMEA)


New Engineering Facility

This new 35,000 sq ft facility (which will include corrosion research labs) will be ready for occupancy by 2010. This project received partial funding from The Timken Foundation.


Integrity Management, Reliability, Performance Assessment and Safety

Dr. Joe H. PayerProfessor of Corrosion and Reliability Engineering

The University of Akron


Performance Assessment, Reliability, Risk Assessment and Safety

Performance assessment to evaluate current status and future performance

• Energy, transportation, communications, water

• Aging structures and equipment are paramount to the U.S.

power plants, transmission, bridges, pipelines, nuclear and other environmental waste

• Advanced, next generation systems with new materials/environment/service

power plants, wind mills, pipelines, bridges

fuel cells, batteries, energy storage, electronics

• Integrity management, performance assessment, life prediction, accelerated testing

How safe is it? How long will it last? How sure are you?


Three Crucial Areas to Reduce Costs and Increase Reliability

(A) Advance Life Prediction

(B) Performance Assessment for Existing and New Systems

(C) Condition Assessment and Life Extension of Aging Infrastructure

Power plants, wind mills, pipelines, bridges

Fuel cells, batteries, energy storage, electronics

How safe? How long? How sure are you? From “Corrosion Costs and Preventive Strategies in the United States’


Integrity Management, Reliability, Performance Assessment and Safety

I. Multi-scale, Multi-level Models for Performance Assessment and ReliabilityII. Determination of Chronological Damage EvolutionIII. Understanding Corrosion Processes at the Molecular Level

Affects both aging infrastructure and advanced, next generation systems

Current practices do not meet present and growing expectations of operators, regulators and the public

Advances in both science and engineering are needed

Major transitional gains are to be realized from enhanced modeling for materials performance and performance assessment.

Affects both aging infrastructure and advanced, next generation systems

Current practices do not meet present and growing expectations of operators, regulators and the public

Advances in both science and engineering are needed

Major transitional gains are to be realized from enhanced modeling for materials performance and performance assessment.


I. Multi-scale, Multi-level Models for Performance Assessment and Reliability

Analysis of Waste Package Performance“Will a metal can last 10,000 yrs?”

Effective Exposed Electrolyte (1)

METAL

CREVICE FORMER

CATHODE (2)DISSOLVING ANODE

Modified Crevice Gap (3)

Effective Homogeneous Electrolyte (4)

Effective Homogeneous

Anolyte (5) Effective Exposed Electrolyte (1)

METAL

CREVICE FORMER

CATHODE (2)DISSOLVING ANODE

Modified Crevice Gap (3)

Effective Homogeneous Electrolyte (4)

Effective Homogeneous

Anolyte (5)

“Linked” multi-length scale corrosion, electrochemistry, chemistry and physics are neededto build the ties between the atomic and engineering application scale


“Linked” multi-length scale physics is needed to build the ties between the atomic and engineering application scales

Courtesy of Rusty Gray, LANL


II. Damage Chronology Depends upon the Metal and the Environment


Chronological Damage Evolution: Experiment, Computation and Visualization

Crevice Most of the potential drop

• Most of the potential drop is in front of the crevice

• The current distribution within the crevice is highly non-uniform

• The diffusion field is similar to the potential field

High current density

Low current density

Crevice Crevice Most of the potential drop

• Most of the potential drop is in front of the crevice

• The current distribution within the crevice is highly non-uniform

• The diffusion field is similar to the potential field



Low current density

Low current density

BASE METAL

CREVICE FORMER

2 gap

BASE METAL

CREVICE FORMER

2 gap

virtual cathode

19 S

BASE METAL

CREVICE FORMER

2 gap

BASE METAL

CREVICE FORMER

2 gap

virtual cathode

BASE METAL

CREVICE FORMER

2 gap

BASE METAL

CREVICE FORMER

2 gap

virtual cathode

19 S19 S

• Conditions are not constant: temporal and spatial changes• Metal (corrosion) and Environment (corrosivity)• A process not an event: Initiation-Propagation-Stifling (slowing)-Arrest (stopping)

Treatments of evolution of environment and evolution of corrosion damage


Documents

Corrosion and Reliability Engineering at The University of Akron September 12, 2015