Corrosion Engineering at Ncercamp

CORROSION ENGINEERING AT NCERCAMP

The National Center for Education and Research on Corrosion and Materials Performance NCERCAMP AT THE UNIVERSITY OF AKRON CONTENTS

Corrosion and materials degradation costs the United States $276 billion Background and Contact Information ...... 1 annually, according to “Corrosion Costs and Preventive Strategies in the United States,” a study released by NACE International and the U.S. Federal Contents...... 2 Highway Administration. With those costs continually rising, UA recognizes a need for skilled corrosion engineers and is the first university in the nation to Equipment Listing...... 3 offer a baccalaureate degree in corrosion engineering. Faculty and Key Stakeholders...... 6 Capitalizing on this unique degree program, the U.S. Department of Defense awarded the University a grant to create the National Center for Education Capabilities...... 9 and Research on Corrosion and Materials Performance (NCERCAMP). NCERCAMP provides corrosion engineering research, testing and analysis Materials Performance Testing...... 10 to provide corrosion and materials performance solutions to industry and government agencies. Materials Characterization...... 11 Materials Development...... 12 The center’s more than 30 interdisciplinary professors and technicians are experts in a wide variety of engineering disciplines, including corrosion, Modeling & Simulation...... 13 chemical, surface, mechanical, civil, electrical and structural engineering, as well as polymer science, applied mathematics and statistics. This unique Microbially Influenced Corrosion (MIC) ...... 14 collection of skillsets allows the center to provide innovative solutions to a wide range of corrosion and materials performance issues. Methods of Collaboration...... 15

For information on how to work with NCERCAMP on a project, please contact us at:

Address: NCERCAMP 264 Wolf Ledges Parkway Email: [email protected] Akron, OH 44325 Website: uakron.edu/ncercamp Telephone: 330-972-6978

Fax: 330-972-5141 EQUIPMENT LIST EQUIPMENT LIST

Equipment Description Equipment Description Equipment Description Equipment Description - Tescan LYRA-3 XMU FIB- Microscopy observations, - CORTEST frame for Hostile environments, - X-Ray computed tomography - X-Ray Diffractometer-thin film FESEM System analytical compositional mechanical tests mechanical testing under GE with dual tube - Sputter Coater with Metal analysis - 1 Gal Autoclave (Hastelloy) high temperature/high - Oven for powder coatings Coatings application and Vacuum Chamber - 150,000 PSI Proof ring test pressure environments - Temperature-relative humidity Controlled environment - Mini temperature film performance, materials system (mechanical testing) cabinet chambers formation bar development and - Atomic Force Microscope with Materials Characterization, - Slow strain rate tests for - Freeze thaw chamber - Climate chamber performance Multimode/Nanoscope surface analysis mechanical testing (2) - Film drying Chamber-Keyence - Thinky centrifugal mixer (nano-scale) coupled - Dedicated Acoustic Emission - MTS Criterion C45.105 Mechanical testing, - Viscosity Rheometer with electrochemical and resistance monitoring for - MTS Landmark 370.10 with materials are exposed to - CM-5 colorimeter measurements burner rig immersion bath chamber heavy loads or cyclic loads, - Dispermat CV3 - Micro hardness tester Coatings sample - Data Acquisition and MTS mechanical performance of - E-coater - Gamry 600 potentiostats (4) CAREs, electrochemical - Microscope for Coating preparation, coatings grips materials is tested - FTIR Spectrometer tests Examination application and - Hot air generator - Film Formation Bar microscopy observations of - High temperature vacuum Composite materials, high - Hysitron Nano Mechanical test - Low temperature freezer - Stereoscopic Microscope – coated materials, sample furnace temperature applications, system - UV processor Omnicure S2000 Olympus SZX16 preparation for coatings - High temperature 6 in. tube materials performance at - Convection oven BlueM - Scanning Auger Nanoprobe - Inverted Microscope AmScope performance tests furnace high temperatures - UV wet powder coatings PH1710 - Ultrasound Gauge, holiday - Furnace 1600C box furnace processor with oven for UV- detector, coating thickness - Grinding bowl and tungsten curable powder coatings gauge ball mill - PVD Deposition Chamber- - Sample cutter JDC Precision - MTS Electromechanical Angstrom - Gardco Scrub resistance D10- - Alicona InFocus G5 surface Surface Characterization, mechanical test system VF characterization microscopy observations - Micro-hardness tester - Film drying chamber - SEM Hitachi TM3030+ with with compositional analysis machining and building EDS - CORTEST high purity Autoclave, high Modern Tool Co. autoclave temperature pressure - Ross high sheer inline mixer - Rotating Cylinder Electrode Wet chemistry, tester - Film drying chamber humidity (15-mm OD) electrochemical control system - Gamry Potentiostats (4) characterization of - VWR refrigerator/freezer - Biologic Potentiostats SP200 materials by means of - Simultaneous TGA/DSC/DTA TGA, materials (2) electrochemical techniques System degradation, high - Extensometer for MTS Burner High temperature test, - Biologic Potentiostat VSP300 temperature exposure Rig materials performance 4-channel - HVOC for burner rig - Modulab Solartron XM - Horizontal high temperature - Dell Precision Computers with Modeling and simulation Electrochemical System test instrument specialized materials software: - DIC with thermal imaging for - Salt spray chambers Environment exposure, PANDAT, ELSYCA, OLI (6) horizontal MTS accelerated corrosion - PPS thermal spray room High tests by aggressive - Struers Tegramin 30 polishing Sample preparation, temperature tests, materials environments machines (2) sample cutting performance - Buehler Abrasimatic 300 cutter and grinding for - Kelvin Probe with Electrochemical electrochemical tests environmental chamber microscopy, surface GAMRY 600 potentiostat with Electrochemical tests - Electrochemical Scanning analysis coupled with - UV VIS Spectrophotometer Materials development EQCM System VersaScan (SECM, electrochemical testing - Force Tensiometer SVET, LEIS, SKP, SDC) - Gamry 8-channel potentiostat GAMRY 600 potentiostat Electrochemical tests - QUV Accelerated weathering Temperature-relative Modeling software Biovia Modeling and simulation - High energy ball mill Materials development tester humidity, coatings - QCT condensation tester degradation tests by - Fluorescence Microscope Materials development UV light and droplets Olympus BX63 motorized XY condensation stage

- CSZ Temperature/Humidity Sensors, controlled - Automatic hydraulic press Materials development tests atmosphere tests - Tube furnace with controlled atmosphere - Grips for Instron mechanical Sensors, controlled testing atmosphere tests - Modeling software COMSOL Modeling and simulation Postdoctoral researcher performs electrochemical testing . Students perform testing on coatings .

FACULTY AND KEY STAKEHOLDERS

- Corrosion of Steel in Concrete - Smart Corrosion Inhibitors Bastidas, David M. Corrosion Engineering - Stainless Steel Corrosion

- Biomolecular Engineering - Antimicrobial Hydrogels Cheng, Gang Chemical Engineering - Antifouling Hydrogels

- Computational Mathematical Models of Corrosion Damage Clemons, Curtis Applied Mathematics - Galvanic Corrosion, Crevice Corrosion - Biofilms FACULTY AND KEY STAKEHOLDERS

- Corrosion Cong, Hongbo Corrosion Engineering - Pitting - Passivity - Microbiology - Biofilms and MIC Ju, Lu-Kwang Chemical Engineering - Fast Characterization - Surface Characterization of Pitting Corrosion Dean of College of Polymer Science Dhinojwala, Ali - Plasma Coatings - Adhesion and Polymer Engineering - Mathematical Modeling of Corrosion Damage Kreider, Kevin Mathematics - Galvanic Corrosion - Surface Engineering of Materials - Crevice Corrosion, Biofilms Doll, Gary Surface Engineering - Tribology - Nanocomposite Materials - Localized Corrosion - Passivity Lillard, Scott Corrosion Engineering - Stress Corrosion Cracking - Curriculum Development and Hydrogen Damage Evans, Ed Chemical Engineering - Environmental Barrier Coatings - Nanomaterials - Fatigue and Fracture of Structural Systems - Structural Behavior and Design Menzemer, Craig Structural Engineering - Material Characterization and - Microstructure and Dynamics of Polymer Systems Full-Scale Experimentation - Thin Films and Near Interfaces Foster, Mark D. Polymer Science - Novel X-Ray and Neutron Scattering Techniques - Water Quality Modeling and Management - Chemical Oxidation Process - Mechanics of Materials Miller, Chris Civil Engineering - Hydraulic Modeling and Structures Gao, Xiaosheng Mechanical Engineering - Fatigue and Fracture Mechanics - Multi-scale Modeling of Damage - Statistics Mimoto, Nao Statistics - Mathematics - Mathematical Modeling - Modeling Corrosion Damage of Corrosion Damage Golovatv, Dmitry Mathematics - Galvanic Corrosion - Crevice Corrosion, Biofilms - Advanced Electrochemical for Corrosion Prevention Monty, Chelsea Chemical Engineering and Mitigation - Novel Metallic and Ceramic Coatings - Monitoring MIC Gupta, Rajeev Kumar Corrosion Engineering - Passivity - High-Temperature Corrosion - High-Temperature Oxidation and Corrosion - Stress, Time, Temperature, Morscher, Greg Mechanical Engineering Hernandez-Maya, - Electrochemistry Environment Interaction Research Scholar - Corrosion and Mechanisms Roberto - Surface Characterization - High-Temperature Ceramic Matrix Composite Systems

- Risk Analysis, Structural Reliability - Surface Modification/Patterning - Performance Assessment of Huang, Qindan Civil Engineering Newby, Bi-min Zhange Chemical Engineering - Polymeric Materials Deterioration Structures - Anifouling Biofilms, MIC - Damage Detection Methods

- Corrosion Damage to Reinforced Concrete and Steel Structures - NDE and Sensors - Life Cycle Analysis and Ida, Nathan Electrical & Computer Engineering - AC Corrosion Patnaik, Anil Structural Engineering Condition Assessment - Antennas - Structural Engineering and Bridge Design and Construction FACULTY AND KEY STAKEHOLDERS

- Leadership Ramsier, Rex Exec. Vice President, Principle Investigator - Surface Interactions (Metals) - Surface Science CAPABILITIES - Systems Analysis and Engineering Sastry, Shiva Electrical Engineering - Wireless Monitoring Systems - Large-Scale Real-Time Systems

- Microbiology Senko, John Geosciences - Microbially Influenced Corrosion NCERCAMP draws from the expertise of more than 30 faculty

- Surface Engineering of Materials members to provide corrosion and materials performance solutions - Tribology Shiller, Paul Surface Engineering - Nanocomposite Materials, Lubrication Strategies to industry and government organizations. The center is home to a multimillion-dollar suite of equipment to provide research, testing - Corrosion-Resistant Coatings Soucek, Mark Polymer Science - Metal Cladding and analysis in many ways. - Coatings Under Insulation

- Mechanical Behavior of Materials Our capabilities are broadly outlined below. - Materials Processing Srivatsa, Tirumalai Mechanical Engineering and Characterization - Influence on Structural Response

- Computational Mathematical Models of Corrosion Damage Young, Gerald Applied Mathematics - Galvanic Corrosion, Crevice Corrosion - Biofilms

- MEMS/NEMS and Lab-on-a-Chip Devices, Smart Materials Materials Performance and Structures • Accelerated Testing Zhe, Jiang “John” Mechanical Engineering - Micro/Nano Actuators, Microfluidics and Nanofluidics - Online Health Monitoring • Mechanical Testing of Rotating Machinery • High-Temperature Testing

- Coatings Performance and Degradation Processes, Materials Characterization Self-Healing Coatings • Zhou, Qixin “Amelia” Corrosion Engineering - Water Treatment and Biodegradation Microscopy - Electromagnetic Compatibility • Spectroscopy • Electrochemistry

- Project Management - Equipment Maintenance Imes, Will Senior Engineering Technician - Facilitator for Safe Working Materials Development Practices and Environment • Coatings • Alloys - Equipment Maintenance • Composites Li, Lingyan Lab Technician - Microscopy Technician - Equipment Training Modeling and Simulation - Financial Compliance Watkins, Katie Office of Research Administration - Financial Oversight • Mathematical Models - Equipment Fee Structure • Atomistic Simulations

Microbially Influenced Corrosion (MIC)

• Characterization of Microbiological Activities • Measurement of Chemical Indicators MATERIALS PERFORMANCE TESTING MATERIALS CHARACTERIZATION

Testing is performed to understand corrosion and material degradation Materials characterization labs offer analytical instrumentation for resistance of a variety of materials. Our wide range of testing equipment liquid, powder, surface and bulk materials analysis and characterization. allows NCERCAMP researchers to accelerate corrosion processes while These resources are available to UA faculty members and students, testing a material’s mechanical properties and its outside researchers and industry. performance in high-temperature environments.

Accelerated Testing A Corrosion Engineering student performs hardness Capabilities testing on a micro-indenter • Expose coated and uncoated panels to aggressive • Corrosion analysis environments to analyze corrosion resistance • Elemental analysis The word “Akron” has been etched onto a sample using • Accelerate damage and predict the • New techniques for testing reliability of Focused Ion Beam technology on NCERCAMP’s SEM . • 3D imaging material’s performance commercial alloys At only 10 µm, this etching is about 1/5 the thickness of • • Material degradation/corrosion processes are • Fatigue crack growth, high-cycle fatigue, In-air and in-liquid imaging a human hair . low-cycle fatigue, fracture toughness, tension accelerated significantly under extreme environmental • Thermal processing and analysis conditions and compression • Chemical composition • Tests simulate effects of sunlight, dew and rain, generating weathering data in a few weeks or months • Crystal structure Microscopy • Performance of metals, polymers and coatings for High-Temperature Testing • Organic, inorganic, soft/hard materials, • Infinite Focus Microscope (IFM) damage including color change, gloss loss, chalking, and coatings • Simulate operating stresses experienced in cracking, crazing, hazing, blistering, embrittlement, • a pressurized water reactor system that is Confocal Laser Scanning Microscopy (CLSM) strength loss and oxidation completely computerized Spectroscopy • Scanning Electron Microscopy/Energy Dispersive • High-temperature, high-velocity (up to Mach 2) X-Ray (SEM/EDX) burner rig testing with capability for sand ingestion • Auger Electron Spectroscopy (AES) Mechanical Testing • Atomic Force Microscopy (AFM) • • Stressed oxidation testing under high-velocity, X-Ray Photoelectron Spectroscopy (XPS) • Kelvin Probe Force Microscopy (KPFM) • Evaluate electrochemical, physical and high-water-content atmosphere up to 1450°C mechanical properties of coatings • Stereomicroscopy • Thermal-barrier-coated (TBC) superalloy system • Qualification of hardness of films and coatings and ceramic matrix composite evaluation • Fluorescence Microscopy of materials varying from polymers to metals • Understand influence of temperature on • Phase Contrast Microscopy • Determination of coating adhesion to substrate structure of metal through nanoscratch testing • X-Ray Diffraction (XRD) • Continuous measurement of oxidation kinetics as • Determination of coating failure mechanisms well as change in metal structure

• Highly localized determination of dynamic • Heat treatments of materials in wide range of mechanical properties atmospheres and temperatures MATERIALS DEVELOPMENT MODELING AND SIMULATION

NCERCAMP researchers strive to prevent corrosion before it begins, rather NCERCAMP utilizes a number of different modeling and simulation than merely manage it. For this reason, we are always working to develop software programs to develop, validate and apply mathematical models new alloys, coatings, composites and other materials that offer superior to predict, prevent and manage corrosion. corrosion resistance as well as outstanding mechanical properties.

Alloys and Composites Capabilities Risk Management

• Synthesis of advanced metallic materials with excellent • Conducting coordinated experimental/modeling of Pitting Corrosion corrosion resistance and mechanical properties investigative approaches using interdisciplinary (AA1050) in teams of mathematicians, statisticians, scientists • Novel, ultra-strong, lightweight, corrosion-resistant and engineers. The approaches combine scientific Atmospheric Conditions materials for auto, marine and aerospace concepts and empirical input • Processing technologies to improve the properties • Constructing atomistic, mesoscale and continuum of commercial alloys scale simulations of deterministic and/or stochastic • Heat treatment of materials models for new or existing designs, and for risk analysis • Metastable/nanostructured materials via high-energy ball milling • Developing analytical solutions and/or numerical simulations (using in-house or commercial • Casting of various alloys and composites computational codes)

• Elucidating the interaction between the environment and the dynamic response of the system Coatings

• Development of novel functional coatings with Applications improved anti-corrosion properties and extended • Atomistic simulations of surface layers, inner layer service lifetime coatings, and binding of coatings to metals • Modification of polymer structure and performance • Crevice corrosion of corrosion-resistant alloys in • Pigments for UV resistance fastener assemblies • Computational simulations/models to • Galvanic corrosion in a variety of industrial metallic predict coating behavior configurations • Development of cure-on-command UV and • Pitting corrosion visible light technology • Combined galvanic, crevice and pitting corrosion • Synthesis of organic and inorganic coatings • Microbially influenced corrosion (MIC) and biofilms • Metallic and ceramic coatings development • Corrosion in coating/metal systems MICROBIALLY INFLUENCED Testing Agreements – Testing agreements are generally CORROSION (MIC) short-term engagements. Organizations will specify requirements, such as what materials they would like to have tested and what testing methods they are looking

Researchers at UA are characterizing the influences of various for. The center will then carry out testing and provide the results to the client. No analysis is performed. microbiological processes on the corrosion of various alloys. We apply a unique combination of innovative electrochemical and microbiological techniques to determine mechanisms and early indicators of microbially Master Research Agreements – Research agreements influenced corrosion (MIC). are typically long-term. Companies will come to us to help find solutions to their corrosion problems. This may involve the sponsorship of a student or a postdoctoral researcher. As the research is conducted, NCERCAMP will provide an analysis of the findings and will provide ongoing recommendations.

UA Research The “ZRA” Technique

• Apply a variety of approaches to • Interrogate MIC in a split-cell format understand the roles of microorganisms in corrosion • Zero-resistance ammetry (ZRA) measurements are collected from two working electrodes (WE) deployed in separate chambers that • Use model microorganisms, organisms are connected by a semipermeable membrane isolated from systems experiencing MIC, and mixed microbial consortia from those • Mimic the conditions associated with heterogeneous coverage systems of metal surfaces by microbial biofilms, while adapting the physicochemical conditions to those • Study microorganisms in situ, including observed in field settings measurements of chemical indicators of microbiological activities and • Monitor processes that occur when metals are exposed to culture-independent approaches to different environmental conditions characterizing microbial communities • UA researchers are currently using this technique to: and activities 1. Determine mechanisms of MIC • Utilize microscopic approaches to surface characterization, and electrochemical 2. D evelop robust rate formulations for MIC approaches to interrogating fluid 3. S ensitively monitor MIC in real time chemistry and solid-solution interfaces (e.g., LP, EIS). For information on how to work with NCERCAMP on a project, please contact us at:

Address: NCERCAMP Email: [email protected] 264 Wolf Ledges Parkway Akron, OH 44325 Website: uakron.edu/ncercamp

Telephone: 330-972-6978

Fax: 330-972-5141