Survey Furthers Development of Corrosion Software...

________________________________ © 2005-2012 CorrDefense Online Magazine

Volume 8, Number 3 Fall 2012 Top Stories

Survey Furthers Development of Corrosion Software Prediction Technology

NAVAIR and Aircraft Makers Express Need for More Sophisticated Tools

By Alan Rose and Keith Legg

Corrosion impacts the safety, function, and readiness of military assets, costing the Department of Defense $22.5 billion each year, according to the DoD Corrosion Policy and Oversight Office. Specifically, for Navy and Marine Corps aviation, this totals $2.6 billion and results in an average of 25 days of corrosion-related non-availability per year for each aircraft on active status.

Corrosion is clearly an enemy for which we need better weapons, since it is estimated that 35 percent of corrosion costs can be avoided by implementing better up-front analysis and design. The corrosion engineer is at a disadvantage when compared to his colleagues in structures and aerodynamics who have access to powerful FEA (Finite Element Analysis) software tools that can predict structural loading and flight response on complex 3-D computational models. As soon as weapons systems are deployed, material characteristics change due to environmental effects. Consequently, coatings and paint systems will degrade and get damaged, but the corrosion engineer does not have a tool to assess the long-term effects of these forms of degradation on the aircraft materials.

"Because airframe designers have stress analysis software, what we as materials and process engineers need is environmental stress analysis software," noted Bob Guillemette, Sikorsky Aircraft Corporation Lead—Corrosion & Prevention Control. Indeed, there have been many developments in corrosion prediction technologies. However, the field is a complex one, entailing many different mechanisms of corrosion and a huge number of variables. So the military departments want to know—where do we invest our time and dollars?

As part of phase one of an Office of Naval Research (ONR) project investigating the feasibility and efficacy of galvanic corrosion prediction from 2011 to 2012, Corrdesa conducted a survey in order to help NAVAIR and aircraft manufacturers such as Sikorsky guide priorities, resources, and investments into the research and development of a corrosion software prediction technology, while also engaging with potential users of these tools.

Key Corrosion Survey Findings

The aim of the survey was to gauge the extent to which the corrosion community was using engineering software tools. Only seven questions were asked, in order to make the survey simple and encourage a wide response. A total of 9,809 questionnaires were sent by email, resulting in final responses from 183, amounting to slightly under two percent (not atypical for e-mail blast surveys). In fact, the result was highly positive, since it meant that in absolute terms, 183 people considered the survey interesting and relevant enough to respond to.

Overall, 70 percent of respondents currently rely on in-house expertise to assess the impact of corrosion on design; however, 83 percent said they would use corrosion prediction software if validated, 57 percent preferred a stand-alone package, and 20 percent stated that such a tool would have to be integrated within their company CAD environment.


The Questions and Responses

The first question was a filter question to ensure that Corrdesa engaged with a relevant sample. Respondents comprising 10.8 percent stated that corrosion did not affect their products, but many of these still continued to answer remaining questions, because they comprised coatings and corrosion mitigation equipment providers. Essentially, corrosion affected their clients' products.

Q1 – Does corrosion affect your products?

Q2 – How is the possible impact of corrosion considered in the design of your products? Although many respondents already use engineering software tools in other aspects of design, less than 20 percent actually use any corrosion prediction software.

The common methods are mainly based on experiential information, such as best practices and the testing of prototypes. This is where we see risk, i.e., how can you be sure that future issues will be identified and predicted based on past experience?

Q3 – Which design engineering software tools does your organization presently use? This question was designed to bring out how familiar the survey sample was with other engineering software tools. As expected, a great use is made of CAD (computer-aided design), with between a third to a half regularly using FEA techniques such as stress, flow, and thermal analysis.


Q4 – If validated, would your organization consider the use of corrosion prediction software?

The response to this question was provocative. There is a great deal of interest in the potential of corrosion prediction software tools, with 82 percent of respondents saying they would consider such tools, assuming, of course, that the tools were qualified and validated.

Q5 – How would you prefer to implement corrosion prediction software?

Underpinning this question was the recognition that the number of product engineers in an organization is disproportionate to the number of those with an acknowledged expertise in corrosion. For example, a large organization such as United Technologies might employ 15,000 product engineers who make many design decisions with corrosion implications, and apply work based upon corrosion engineering standards. Next, there might be around 1,000 materials engineers who "own" the actual corrosion engineering standards and work process. However, within such an organization, only 45 corrosion engineers might actually possess the specialist's knowledge to develop and validate tools for the standards practices, and the methods for obtaining data. Consequently, if developers create software tools for corrosion prediction, it is very important to consider how a user community would implement such tools. It might be the best and most accurate software in the world, but if an organization cannot see how it fits into their design workflow it will simply not be used. With this question in mind Corrdesa envisioned two model users;

the materials and process engineer who would be more familiar with corrosion fundamentals

the design engineer who would be more familiar with good design practice but not necessarily materials fundamentals

The materials and process engineer would probably use 'stand-alone' software, and the design engineer would use some type of CAD-integrated version. Among the survey respondents, two-thirds of those open to using corrosion prediction software would prefer access as a stand-alone tool. This result raised the following question: Does this preference indicate a desire to keep such tools within the control of the specialists? Maybe such a scenario could be a step along the way, and when the software capabilities and limitations have been clearly defined, there might be greater acceptance of a CAD-integrated tool. However, on further analysis, the survey revealed that individuals that preferred CAD-integration were generally from the larger, established organizations.


Q6 – How would you use corrosion prediction software?

This question was more specific, in order that Corrdesa might understand where such a tool would be applied in order to deliver value to the design process. It seems that a major challenge is to quickly understand the impact of changes, a challenge that is understandable against a backdrop of new material/composite introductions and a substantial influence of growing environmental legislation that severely affects the choice of protective coatings. (An example is the industry's move away from cadmium to zinc-nickel.)

Q7 – How important or relevant would you rate the following corrosion mechanisms for your products?

There are many corrosion mechanisms, and only some of them were mentioned in this survey. However, Corrdesa found it very interesting that galvanic corrosion was cited so highly. The physics of galvanic corrosion have been studied extensively, and it is believed that we can now predict the galvanic reaction behavior from our growing understanding of the physics and chemical processes underlying this phenomenon. Software tools already exist to predict galvanic corrosion on complex assemblies of mixed materials. There would be further value in clearly understanding the impact of galvanic corrosion, since it is believed that this mechanism is a precursor to 80 percent of the corrosion and fatigue issues experienced on naval aircraft. Indeed, other mechanisms cited highly were localized corrosion resulting from pitting and crevices.

Conclusion

Organizations heavily rely on expertise and established practices supported by testing when it comes to delivering corrosion-resistant designs. However, there is a substantial interest in adopting corrosion prediction software tools particularly for the top-cited mechanisms of galvanic, pitting, and crevice corrosion.

________________________________ Page 1 © 2005-2012 CorrDefense Online Magazine


DoD Releases Guide on Alternatives to Hex Chrome

By Chris Grethlein

In September 2012 the Department of Defense released a new guide for weapons systems program managers to assist them in choosing alternatives to hexavalent chromium (CrVI), known colloquially as hex chrome. The DoD Corrosion Policy and Oversight Office developed the guide with assistance from the DoD Corrosion Prevention and Control Integrated Product Team, comprising materials experts from across the military departments, AMMTIAC, and LMI Government Consulting. (See New Tool Helps DoD Weigh Hex Chrome Alternatives.)

The guide is titled Analysis of Alternatives to Hexavalent Chromium: A Program Management Guide to Minimize CrVI Use (Spiral 1). It has been released to the public and can be downloaded in pdf format from the report title link above.

The guide is a compendium of information resources that provide an extensive summary of the policy, programmatic, technical, safety, and regulatory issues pertaining to the restricted use of hex chrome. "This publication was created as a resource to aid those in the acquisition community who make design and procurement decisions," said Daniel J. Dunmire, director of the Corrosion Policy and Oversight Office.

The controversy surrounding hex chrome is emblematic of the larger issue of balancing the defense needs of the nation against the desire for a cleaner environment and a safer workplace. Meeting these two goals simultaneously presents unique challenges. Weapons system program offices and their program managers must navigate through this sea of conflicting requirements to arrive at a solution that sufficiently meets both interests.

The guidebook highlights include:

An overview of the challenges and strategies associated with the use or omission of hex chrome.

A synopsis of the environmental, safety, and occupational health problems associated with hex chrome, where and how hex chrome is used in the military, and the impact that using alternatives to hex chrome may have on military systems during their service lives.

A summary of the policies, regulations, and DoD memoranda regarding the use of hex chrome.

Procedures and strategies for evaluating and validating hex chrome alternatives. It also identifies resources available to program managers as they conduct their material down-select process. Written with the program manager in mind, this section addresses the myriad issues that program managers will need to address when considering potential applications of hex chrome.

An alternative to the hex chrome qualification and selection process. This particular alternative is designed to serve as an engineering reference for technical personnel. The process, expressed both in text and as a flowchart, describes the recommended material selection process to evaluate and assess the suitability of alternative materials for various systems. As part of the process, it also specifies when using hex chrome would be the best option, which typically means when there is no acceptable alternative.

http://corrdefense.nace.org/corrdefense_summer_2011/top_story4_NoSidebar.asp

http://ammtiac.alionscience.com/pdf/AMMT-39.pdf

http://ammtiac.alionscience.com/pdf/AMMT-39.pdf


An analysis of alternatives. This includes summary information and compiled data collected relative to the performance of alternatives, compared to traditional hex chrome material systems.

Protecting the nation's weapon systems and military infrastructure from the scourges of corrosion is a constant and ongoing challenge. For many decades, the "gold standard" in corrosion prevention and control has been the use of preventative compounds containing chromates—specifically those formulated from hex chrome. These compounds have a long history of success in protecting durable assets, having accrued an extensive knowledge base from decades of judicious application. While it remains an industry staple, hex chrome is a known carcinogen that can pose serious health and safety risks to workers and adversely impact the environment.

Recent changes in EPA (Environmental Protection Agency) and OSHA (Occupational Safety and Health Administration) regulations place tighter constraints on using hex chrome, but do not ban it outright. However, without mature alternatives that perform at the level of hex chrome, the DoD will continue to need to use hex chrome for applications in which no alternative is determined to be acceptable. Using alternatives to hex chrome, while often necessary, comes with a high degree of risk. It is incumbent upon program offices to mitigate these risks through diligent testing and the evaluation of potential alternatives.

Program managers and their engineering staffs will benefit from having this guide as a reference, as it will help their program successfully pass each milestone in an increasingly complex acquisition environment.



Department of Defense Major Corrosion Events: The Way Ahead

By Cynthia Greenwood

Presidential initiatives have been underway in 2012 to enhance efficiency in spending within the federal government. In keeping with this focus on cost-consciousness, Frank Kendall, Under Secretary of Defense for Acquisition, Technology, and Logistics, issued a memo on June 7, which directs agencies under his purview to review their involvement in conferences that cost more than $100,000.

Although the Corrosion Policy and Oversight Office remains alert to ongoing changes in the procedures required to follow the guidance contained within Mr. Kendall's memo and other federal directives, the Corrosion Office recognizes that, under the law, the mission of the DoD corrosion community of experts must continue and remain a critical DoD focal point.

In keeping with initiatives that would enhance efficiency in federal spending, the Corrosion Policy and Oversight Office has modified the way in which it executes its upcoming DoD corrosion conferences. The key purpose of these corrosion forums as conduits for collaboration and information sharing among federal entities, industry, and academia remains of paramount importance. The way ahead for the major corrosion events between 2013 through 2017 will proceed as follows:

DoD Corrosion Conference 2013 -September 16-17, 2013

In lieu of the planned 2013 five-day forum scheduled to occur at the Sheraton Waikiki hotel in Honolulu, the DoD Corrosion Conference 2013 will take place for the first time via a Web-enabled conference. For this event, the DoD Corrosion Policy and Oversight Office will proceed with its planned call for technical papers from experts across the corrosion community. Submissions will be evaluated by the technical organizing committee, led by the Department of the Air Force, and presented during the Web-enabled event. Logistical details related to logging in to the conference will be forthcoming. Please click here to view the Call for Papers.

DoD Corrosion Day 2013 - September 10, 2013

NACE International is sponsoring a DoD Corrosion Day in conjunction with its 2013 Western Area Conference. This session, which will take place at the Modern Honolulu Hotel, will focus specifically on corrosion prevention and mitigation information and training. The session will be open to uniformed military personnel, government employees, and

http://events.nace.org/conferences/DoD2013/callforpapers.asp


contractors working in the materials degradation field. Personnel operating at other Pacific Rim facilities and locations and are also encouraged to attend.

DoD Corrosion Praxis 2014 - August 19-23, 2014

Coordination is underway for the first-ever DoD Corrosion Praxis. This non-technical event will explore the intersection between corrosion education and practice, and will serve as a medium for the exchange of best practices in combating material degradation of equipment and infrastructure. Emphasis will be placed on a variety of topics to include policy, procedures, training, and implementation. However, for this event, there will be no call for technical papers. The DoD Corrosion Praxis is tentatively scheduled for August 19-23, 2014, in Baltimore, Maryland.

DoD Corrosion Conference Beyond 2014

Following 2014, the schedule for the DoD Corrosion Conference is currently planned as follows:

Pittsburgh, Pennsylvania / August 2015

Cleveland, Ohio / 2017 (dates to be discussed)

As the Corrosion Policy and Oversight Office continues to operate under an uncertain future of resources and funding, the focus of our mission for corrosion mitigation and prevention, in support of the joint efforts of each military department, will endure as a high priority. Flexibility and adaptability in the near-term will allow us to maintain the forward momentum in the ongoing war against material degradation, and secure an advantage in the long-term.



DoD Corrosion Office Opens Call for Papers for 2013 Web-Enabled Conference


The DoD Corrosion Policy and Oversight Office is now accepting technical papers from experts across the community for its 2013 Web-enabled conference, which is slated to go live from 1 to 5 p.m. Eastern Standard Time, respectively, on September 16th and 17th, 2013.

"The 2013 conference will be conducted entirely online so we can provide access to as many attendees as possible worldwide, and to reduce the costs of travel for all participating Service and industry experts," said Daniel J. Dunmire, director of the DoD Corrosion Policy and Oversight Office. "NACE International will facilitate the Web-enabled format of the online teleconference. By inaugurating this format in 2013, we expect to attract military program managers of weapons systems and

facilities, as well as a wide range of corrosion experts across the DoD acquisition community."

"The 2013 DoD Corrosion Conference program will feature multiple symposia tracks, each of which will comprise multiple papers," noted Rich Hays, deputy director of the DoD Corrosion Office. "We are scheduling presentations on two consecutive afternoons in order to make the sessions available to participants headquartered across several time zones. Logistics related to logging into the teleconference will be forthcoming. While it is possible that not all submitted papers will be presented during the Web-enabled conference, all submitted and peer-reviewed papers will appear in the conference proceedings."

Abstract submissions will be evaluated by a technical organizing committee led by the Department of the Air Force. Abstracts are welcome on the following topics: Corrosion Science, Sustainment, Policy, Acquisition/Life Cycle, Corrosion-Resistant Materials, Corrosion Technology Transitions and Evaluations, and Facilities and Infrastructure. Click here to submit your abstract and to view more detailed instructions.

http://events.nace.org/conferences/DoD2013/index.asp



"The Corrosion Experience"

2013 Exhibit Unlocks the Mysteries of Degradation for the Next Generation


The forces that drive the breakdown of infrastructure can be complex enough for corrosion scientists to apprehend. But for non-experts, the factors that cause steel bridges to collapse or fighter jet airframes to crack are even harder to grasp.

To help prevent catastrophic failures like the collapse of the I-35 West Bridge over the Mississippi River in Minneapolis, the next generation needs to know more.

Understanding the forces underlying the breakdown of bridges, pipelines, and waterways requires a direct experience with the science underlying such mysteries. The DoD Corrosion Policy and Oversight Office will spotlight the natural phenomena that lead to corrosion and material degradation in a

novel exhibit aimed at the next generation of infrastructure preservationists.

Featuring computerized simulation games designed for middle and high school students, "The Corrosion Experience: The War on Corrosion" opens in March 2013 at the Orlando Science Center in Orlando, Florida. Actor LeVar Burton will preside over the exhibit grand opening and ribbon-cutting ceremony from 8:30 to 9:15 a.m. on March 16, 2013.

When visitors enter the "The Corrosion Experience," they will stand beneath a 200-square-foot trestle bridge made of rusty steel. Beneath this towering canopy of corrosion, they can choose from a menu of virtual experiences that graphically depict the science of corrosion and the industrial processes used to prevent it. For users, these experiences are simulated using 3-D mapping technology.

In the CorrSim Jr. game, for example, students stand in front of a TV that tracks their movements much like a Kinect home video game. "By moving their hands in front of the screen, visitors can replicate the process of sanding, blasting, priming, and painting," noted Anne Hanson, manager of Continuing Education and Outreach at The University of Akron's National Center for Education and Research on Corrosion and Materials Performance (NCERCAMP). "Each of these processes is vital when coatings are properly applied to ships, aircraft, cars, trains, and commercial structures."

"At DoD we believe middle and high school students should be exposed to the challenges that all communities face as they preserve their local infrastructure," said Daniel J. Dunmire, director of the DoD Corrosion Office. The exhibit's 3-D mapping technology also invites students to perform other

Concept design courtesy of Echo Artz.



interactive experiments to understand how engineers preserve drinking waterways, bridge and highway systems, and vital forms of public and private transportation.

At the Corrosion Rack display, students take a hand-held microscope and hold it up to different coupons or samples, in order to appreciate how scientists collect data to discern how environmental and weather conditions can degrade materials in different ways. "The coupons include different types of metals that have been exposed to harsh elements such as salty air, wind, rain, and saltwater," Hanson said.

To help students understand how metal oxidizes and the chemical processes underlying erosion, for instance, different examples of the twelve forms of corrosion will be hidden around the major exhibits. "Students will assume the role of inspector and seek out specific examples of fretting, pitting, and galvanic corrosion, for instance," Hanson said.

"Both the Corrosion Rack and the corrosion discovery game are designed to expose students to the scientific mysteries underlying corrosion and its chemical and electrochemical origins," Dunmire said.

At the exhibit's Career Kiosk, students can learn from subject matter experts who maintain the myriad aircraft, ground vehicles, and facilities comprising the nation's infrastructure. "The kiosk allows visitors to understand the entire range of career specialties that comprise the field of corrosion science and engineering," said Susan Louscher, executive director of NCERCAMP. "At the kiosk, visitors can hear from inspectors, painters, technicians, corrosion engineers, and scientific researchers that represent industry, DoD, and universities with a corrosion engineering focus."

"The Corrosion Experience" will also feature artifacts from different sectors of industry and government to underscore the chemical, electrochemical, and geological processes inherent in corrosion and degradation.

"The causes of corrosion on our bridges, highways, and pipelines are rooted in complex scientific processes, and this new DoD-sponsored science exhibit unlocks the secret of those processes and how they can be mitigated," Dunmire said.



Volume 8, Number 3 Fall 2012 Featured Projects

New Army Roof Fights Corrosion and Generates Power

By Chris Grethlein

The U.S. Army Engineer Research and Development Center, Construction Engineering Research Laboratory (ERDC/CERL) has implemented a novel multifunctional solution to address two major facilities-related challenges at once—preventing corrosion and reducing energy consumption. In a pilot program at Kilauea Military Camp in Hawaii, ERDC/CERL targeted a 5,500-square-foot vehicle storage building for refurbishment, which had a highly corroded corrugated metal roof. The refurbishment used a system that incorporates a standing seam metal roof having a high-performance coating and photovoltaic cells based on thin-film solar technology.

Hawaii is a very corrosive environment for military infrastructure. The physical structures of the Kilauea Military Camp are subject to a harsh environment of alternating rainstorms and searing, radiant sunlight—conditions typical of Hawaii's many unique microclimates. Many of the buildings at the camp

experience severe corrosion problems as a direct result of the rain and associated humidity, exacerbated by the heat and ultraviolet exposure from the sun. As expected, corrosion manifests itself most harshly on the metal roofs of these buildings, which are used to protect occupants, mission-essential materiel, spare parts, and maintenance equipment from the tropical rains and the hot, humid environment.

Reducing Consumption through Alternative Energy

Corrosion isn't the only pressing problem for military facilities. Following recent changes in DoD policies, all military installations are now directed to reduce their reliance on conventionally supplied electric power, particularly when it is generated from fossil fuels. To minimize pollution from fossil fuel power plant emissions, the state of Hawaii is encouraging greater use of cheap alternative sources of electric power, preferably from renewable sources.

Following Army policy and Hawaii state directives, Kilauea Military Camp is seeking alternative energy approaches that are environmentally sustainable. To demonstrate such technologies, ERDC/CERL and the Kilauea Military Camp Public Works office have integrated photovoltaic cells with a new standing seam metal roof on building 84. (See The Science Behind Thin-Film Solar Technology.) This technology uses a free and plentiful energy source, the sun, with little environmental impact. Moreover, the photovoltaic components are thin-filmed laminates—flat modules that are adhered to the metal roof-anel surface. They do not require racks for mounting, as with conventional photovoltaic technology.

Even at a distance, the severe weathering of this roof at Kilauea Military Camp, Hawaii, is evident. Photo courtesy of U.S. Army Corps of Engineers ERDC-CERL.

The integrated roof panels are first assembled on the ground, and then raised into place as single units. Photo courtesy of ERDC-CERL.


Thin-film solar cell technology has been used in the commercial sector for some time, but this is one of the first military applications of the technology that is being monitored for its energy output as well as its impact on corrosion resistance when integrated with metal roofing. According to Dave Bailey, ERDC/CERL project manager, "While the power produced by these integrated roof systems is dependent on the scale of application, the product's manufacturer claims power ratings for such solar modules ranging from 10 to 100 watts at peak demand hours. Kilauea Military Camp also expects to realize significant improvements in the service life of the roof by using standing seam metal roofing with a high-performance coating."

Under nominal conditions, the photovoltaic cells could offset up to 25 percent of the load for the building, previously supplied through the commercial grid, Bailey noted. "At such times, the excess electricity will be distributed back to the local Kilauea Military Camp grid."

Benefits to Other Services

The results of this pilot project will be watched carefully, as photovoltaic systems could potentially save a substantial amount of energy used over the lifetime of the building, Bailey noted. Over the next ten years, Kilauea Military Camp is scheduled to undergo major upgrades to the bulk of its facilities. If this initial pilot effort yields sufficiently positive results, it could lead to many additional applications of this corrosion resistant/photovoltaic roof system. The other services and the Coast Guard are also interested in seeing the outcome of this project, since many of their installations include buildings with similar roof-deterioration problems. They also share the same need for environmentally sustainable electric power.



The Science Behind Thin-Film Solar Technology

By Chris Grethlein

Corrosion-resistant roofs with integrated photovoltaic cells take advantage of two emerging technologies to provide both sustainable roofing and electric power.

All solar cells require a light-absorbing material contained within the cell structure to absorb photons, which subsequently generates electrons via the photovoltaic effect. The materials used in solar cells preferentially absorb the wavelengths of solar light that reach the earth's surface. Thin-film solar cells are available as appliqués that are bonded to the corrosion-resistant metal roofing panels prior to mounting the integrated photovoltaic roof panels in place. These solar cell appliqués are composed of three layers of semiconducting materials stacked one on top of the other. Each layer is engineered to absorb a different portion of the solar energy spectrum (red, green, blue) to provide maximum sunlight absorption and a more efficient conversion of solar energy into electric power.

Last, the electrical output of all the panels on a roof is combined and then converted from DC to AC power through a device called an inverter, and finally routed to the standard 110-volt/220-volt AC outlets within the building to power equipment and systems.



NASA Launches Study of Corrosion Exposure Testing

Corrosion Technology Laboratory Investigates Method to Correlate Marine Atmospheric Exposure Tests with Accelerated Corrosion Tests

By Kathy Riggs Larsen

Corrosion protection is a high priority at NASA. The NASA launch facilities at John F. Kennedy Space Center (KSC) are positioned within 1,000 feet of the Atlantic Ocean on Merritt Island, a location that exposes them to salty ocean air, high ambient air temperatures, and extensive ultraviolet (UV) light combined with acidic rocket exhaust from launch vehicles. To provide corrosion control-related technical innovations and engineering services for NASA's launch and ground support structures at KSC, as well as DoD and other customers, KSC maintains the Corrosion Technology Laboratory, which combines people, equipment, and facilities to support state-of-the-art corrosion research and testing.

In June 2010, Corrosion Technology Laboratory researchers began a study to correlate results of exposure tests to determine if accelerated corrosion testing techniques could be reliably correlated to NASA's long-term atmospheric exposure. Specifically, the study used a timescale to measure the time it takes a sample placed under corrosive conditions in each test to reach a similar, if not the same, corrosion rate. Lab officials set out to determine how many hours of

exposure in an accelerated test environment such as a neutral salt spray fog chamber would correlate to one year of atmospheric corrosion at KSC's Beachside Atmospheric Corrosion Test Site.

"We began this project in order to better understand our corrosion environment and determine the feasibility of using accelerated techniques in our coatings qualification process," said Eliza Montgomery, postdoctoral research fellow at the KSC Corrosion Technology Laboratory. With successful correlation, more reliable accelerated tests could be developed for faster material qualification times, she explained. Alternatively, accelerated tests might also be ruled out in many cases if correlation is unsuccessful.

"One of the challenges of corrosion is that there are many parameters or factors involved. Realistically you cannot duplicate all those factors in an accelerated corrosion test, but there may be some factors that have a more significant impact than others," said Luz Marina Calle, senior materials research scientist at the NASA Corrosion Technology Laboratory. The research project will enable Montgomery, Calle, and other lab researchers to better understand why the tests do or do not correlate, and possibly assist them in developing accelerated exposure tests that make up for what the current accelerated corrosion testing techniques lack.

The Beachside Corrosion Test Site at Kennedy Space Center (KSC) includes around 600 feet of test racks for long-term atmospheric corrosion test specimens, which are exposed to the aggressive marine environment of the Atlantic Ocean. Photo courtesy of NASA.


Researching Exposure Testing Techniques

The study's corrosion exposure tests used sample panels made of 1010 carbon steel, the type of steel used to construct the launch structures at KSC. The researchers compared results of long-term atmospheric exposure testing with results from two accelerated corrosion testing techniques—NASA's alternating seawater spray test and the ASTM B117 neutral salt spray fog method. For the long-term atmospheric exposure test, carbon steel panels were placed on the KSC Beachside Atmospheric Corrosion Test Site racks at 30-degree angles. Additionally, data were recorded on atmospheric conditions at the test site, including temperature, relative humidity, total precipitation, chloride deposition, sulfur concentration, and wave height. Data for exposure duration times were collected over three sets of timeframes: one month, successive months, and one year.

During the alternating salt spray test, carbon steel panels were placed at 30-degree angles on test racks at KSC's Beachside Atmospheric Corrosion Test Site close to the atmospheric exposure test racks. Here they were continuously exposed to the same atmospheric conditions as the atmospheric exposure test site, and also exposed to seawater spray for 10 minutes every hour, 24 hours a day, for periods lasting 30, 60, 120, and 180 days. The neutral salt spray fog test exposed the carbon steel panels in a 5 percent sodium chloride neutral salt spray fog chamber for 100; 250; 470; 500; 750; 1,000; 1,500; and 1,900 hours using the ASTM B117 method.

The researchers compared the corrosion rates and corrosion behaviors of the panels in the atmospheric exposure and accelerated exposure environments to identify possible timescale correlations. They measured corrosion rates for all panels using the ASTM G1 weight loss method, and used visual and x-ray photoelectron spectroscopy methods to identify the initial corrosion products. The initial corrosion rates were compared to longer-term data to measure the consistency and sustainability of the corrosion rates as a function of exposure time.

Challenges Presented by Correlating the Results

When trying to correlate the results of the exposure tests, however, they faced several challenges. One problem was trying to relate data collected on the atmospheric conditions, which synergistically and simultaneously influenced the corrosion rates. Montgomery noted that many atmospheric variables affected the atmospheric exposure corrosion rate, which didn't remain constant over time but fluctuated depending on varying atmospheric conditions at different times of the year.

Additionally, the accelerated corrosion test data showed the corrosion rates to be the same after short exposure times and long exposure times, and these rates were much higher than any corrosion rate recorded over a one-year period in the atmospheric corrosion test.

Another challenge in correlating results of the three exposure tests involved factoring in differences in the corrosion products formed on

the sample panels, which also affect the corrosion rates. The salt fog chamber induced a carbon steel corrosion product that became localized where moisture droplets formed and then created a stream of water across the surface. The resulting corrosion products had a low density, were flaky, and formed as vertical ridges.

The corrosion effect of solid rocket booster exhaust on KSC launch pad structures is shown just after a launch and before refurbishment. Photo courtesy of NASA.

Over the years, thousands of samples have been tested on the atmospheric exposure test racks at the KSC Beachside Corrosion Test Site. Photo courtesy of NASA.


The alternating salt spray test produced an aggressive corrosion product along the path of the seawater stream, as well as general atmospheric corrosion that formed across the surface when the salt spray was not operating. The corrosion products formed as blisters and were much denser than in the case of the neutral salt spray fog chamber. The atmospheric exposure caused corrosion to initially occur at local anodic sites and then form as general corrosion across the metal surface. There were no preferentially corroding areas, and the corrosion products were more diverse and dense than those formed during the accelerated tests.

Samples on the alternating salt spray test rack were exposed to seawater spray for 10 minutes every hour, 24 hours a day, during various exposure time frames. Photo courtesy of NASA.

The researchers determined that corrosion rates for long-term atmospheric corrosion and accelerated corrosion testing were poor values to use for data correlation, because the conditions of the accelerated corrosion tests were far too destructive to make a reliable comparison to atmospheric exposure conditions. "When we looked at just the corrosion rates, we could make the time scales correlate, but the data weren't even remotely realistic. That was the problem," said Montgomery. "What we really measured was the aggressiveness of the accelerated corrosion tests."

Although the researchers concluded that it is impractical to correlate the neutral salt spray fog test data with atmospheric exposure test data, they believe the alternating salt spray test is the best candidate for correlating data with the atmospheric exposure tests because it shares the same atmospheric conditions and has the capability to accelerate corrosion with the seawater spray pumped from the ocean. Now they are focusing on developing the alternating salt spray test as a more reliable accelerated corrosion test.

The next steps for correlating the testing techniques, Montgomery noted, include shortening the test exposure times to determine if any timescales can be correlated, measuring surface oxides to determine the main differences between the corrosion products formed during the tests, and understanding which factors may limit the correlation of alternating salt spray test results to atmospheric exposure results.

"The project has been challenging but has provided very useful information," said Calle. "We're hoping that we will be able to develop a more accurate accelerated corrosion test than what is available now."

Editor's note: A version of this article originally appeared in the September 2012 issue of Materials Performance magazine.



Getting It Right the First Time

New Ship Inspection Tool Keeps Hard-To-Reach Places Safe From Corrosion

By Chris Grethlein

Researchers at the Naval Surface Warfare Center (NSWC), Carderock Division, have developed an enhanced ultraviolet (UV) inspection tool to ensure that the thousands of tanks and enclosed spaces on Navy ships are refurbished properly and fully protected from corrosion for years to come.

There are approximately 18,255 tanks on U.S. Navy ships. These spaces are categorized as ballast tanks, fuel or compensated fuel tanks, potable water tanks, and collection and holding tanks, among others. When ships are brought into dry-dock after several years of service for overhaul, their myriad tanks must be emptied, cleaned, decontaminated, and re-coated. Recently the Navy has learned that many of these tanks are presenting corrosion problems well ahead of their next maintenance interval.

A detailed analysis of the corrosion problem indicated that for ships in dry-dock, the surfaces of many of these spaces had been contaminated with hydrocarbons when they were coated. Over time, these hydrocarbons had undermined the tank coatings' performance. Because each of these spaces had previously been decontaminated, inspected to standard, and declared "contaminant free" prior to coating, officials determined that a small amount of hydrocarbons had been present in the tanks. This amount was too small to detect, but it was enough to inhibit bonding during the coating process.

New Tool uses UV Light-Enhanced Technology

To solve the problem, NSWC developed a tool that can detect traces of hydrocarbon contaminants that are below what can be visibly discerned on steel surfaces. UV light improves the ability of inspectors to detect some hydrocarbon contaminants, because most organic materials fluoresce when exposed to it. NSWC's new UV light inspection kit is a super-high-intensity black light that combines a Micro Discharge Light technology with a heat-resistant, polymer lamp head and works with both AC and DC voltage for portability. The technology represents the current state-of-the-art for detection of hydrocarbon contamination.

UV "Black Light" inspection requires a dark room and black light source for inspection of parts. This method is a pass/fail test that will work on any material with a contaminant that fluoresces. The inspector simply places the part under the black light and notes any areas of fluorescence. Experimental results have proven that the UV method can detect the presence of hydrocarbons on a steel surface in amounts far below the visible detection threshold, and thus makes a far superior detector of surface contamination, NSWC officials report.

The ultraviolet (UV) light kit is portable and can detect most hydrocarbons. Photo courtesy of Naval Surface Warfare Center (NSWC), Carderock Division.


New Paints Susceptible to Hydrocarbon Contamination

The detection of hydrocarbon contamination is a growing concern as the Navy moves to higher-solids and single-coat paints. These new paints use less hazardous solvents, but are more sensitive to the effects of contamination. In service, most ship tanks are exposed to one or more hydrocarbon contaminants such as fuel oil, oily waste, machine oil, and grease from cooking operations, some of which are deposited on the surface of the tank. Also, when the coatings within these tanks degrade, the products of their decomposition, which have now become contaminants themselves, will be deposited on the steel. During repair operations, these contaminants must be removed from the steel prior to coating application in order to achieve acceptable coating performance and longevity.

The Naval Sea Systems Command's (NAVSEA's) current standard acknowledges that low-level and trace organic contamination is known to degrade coating adhesion, but presently, it only requires a visual inspection of surfaces to detect oil and grease contamination. So the Navy required a more effective technique to "detect the previously undetectable."

The premature failure of coatings in one of these tanks can be very costly to repair in terms of manpower, mission performance, and ship availability. Photo courtesy of NSWC, Carderock.


Volume 8, Number 3 Fall 2012 Featured Project

Road Conditions Inspire Eighth-Grader to Investigate Concrete Corrosion

CorrDefense Featured Interview

A year ago 13-year-old Lisa Criscione noticed that a fairly young, rebar-reinforced concrete street near her house in Seven Hills, Ohio, showed signs of severe rusting similar to a nearby road that had seen a half-century of wear. Criscione, then an eighth-grader at Incarnate Word Academy, wondered why the younger street was rusting just as badly as the older one. The question led her to formulate the hypothesis and central question of her award-winning research into the causes of corrosion in concrete.

In this CorrDefense featured interview, editor-at-large Cynthia Greenwood talks with Criscione about the provenance and evolution of her 2011-2012 science fair project, which piqued the interest of two University of Akron engineering professors and the Defense Department Corrosion Policy and Oversight Office. Criscione's science project—"Rusty Concrete: Will Too Much Water Corrode Concrete Faster?"—earned numerous local, district, and state fair awards, recognitions from five national professional societies, and a place in the Broadcom MASTERS (Math, Applied Science, Technology and Engineering for Rising Stars) national competition that was held in Washington D.C. from September 28-October 3, 2012. It is an advanced competition that allows sixth-, seventh-, and eighth-graders to demonstrate their science, engineering, and math skills through hands-on team activities. Currently Criscione is in the ninth grade at Walsh Jesuit High School.

CorrDefense: Exactly how did you come up with the idea for your science fair project?

Lisa Criscione: When I noticed that a 50-year-old road in my neighborhood was rusting just as badly as a nearby road that was much newer, I thought about it and remembered that the younger road had been built in the rain. That's how I came up with my hypothesis—"If too much water is in the concrete mix, the faster the rust will appear on the concrete surface."

CorrDefense: I understand that you gave up on the idea of performing the necessary laboratory experiments in your house basement and sought help from several companies and area universities.

Lisa Criscione: Yes, my mother did not want me setting up cement samples and trying to cut rebar in our basement. So she contacted the deans of several local civil engineering departments and the Society of Women Engineers. She was told to contact Dr. Anil Patnaik, a professor in the Civil Engineering Department at the University of Akron (UA). She asked Dr. Patnaik if he could help me accelerate corrosion for my science project.

Standing before the poster display of her "Rusty Concrete" project during the 2012 Broadcom MASTERS national competition, Lisa Criscione holds a two-inch-diameter PVC (polyvinyl chloride) cylindrical mold that she used to make a concrete sample. Below the mold, in her right hand, she holds an actual concrete sample that was corroded in the corrosion cell. Photo by IML Photography, SSP (Society for Science and the Public).


CorrDefense: Whom did you work with at UA and how did you conduct your experiment?

Lisa Criscione: I was invited to join Dr. Patnaik's team of three undergraduates and two graduate students. One of the grad students, Jeremy Lewis, was my supervisor and mentor. He helped me understand the chemistry I needed for my research. In the university's Corrosion Lab, I made two batches of concrete with varying levels of water content and ended up with four samples from each batch. I reinforced each sample with rebar so it would be like the roads in my neighborhood. I let them cure. Then I took one sample from each batch and hooked it up to a corrosion cell. I ran an electrical current through each of them. I used a Webcam to record when rust first appeared on the surface of the sample. After two days, from the videos, I could determine that the sample with more water corroded faster than the one with less water. You could clearly see the rust showing. I repeated the experiment three more times and got the same results. It proved my hypothesis was right.

CorrDefense: What calculations did you use to account for chemical changes that were taking place?

Lisa Criscione: I used Faraday's Law to determine the amp setting needed for the target level of corrosion. I needed .2 amps to generate two percent corrosion. When the concrete has more water, the extra water in the sample causes microscopic air pockets to form. These large pockets make a maze for the rust to follow. Because the pores were bigger, there was less of a tortuous path for the rust to follow. In contrast, the concrete sample with less water formed a more complicated maze for the rust to follow.

CorrDefense: What are the most important implications of your conclusions?

Lisa Criscione: The more water concrete contains, the faster rust will appear on its surface. The corrosion of roads and bridges costs taxpayers billions of dollars and poses a safety risk. I like this project because I'm interested in making Ohio a safer place to live.

CorrDefense: When did you start exhibiting your project? I understand that in addition to Anil Patnaik, you interacted with

Joe Payer, the chief scientist and research program director of the UA National Center for Education and Research on Corrosion and Materials Performance (NCERCAMP), and Rich Hays, deputy director of the DoD Corrosion Office.

Lisa Criscione: I gave a 30-minute PowerPoint presentation in front of Dr. Patnaik's team and Dr. Joe Payer, who listened to the presentations. Dr. Payer then invited me to display my project on a poster at the Department of Defense Corrosion Conference at UA last December, alongside those of the other college students who attended. I got to meet Mr. Richard Hays at the conference. His presentation helped me realize what a big problem corrosion is for our military. At the conference I was allowed to discuss my project and ideas with UA professors and other corrosion professionals. It helped prepare me for my future science fairs. I went on to compete in two local science fairs, a district fair, the state fair of Ohio, the Northeast Ohio Science and Engineering Fair (NEOSEF), and the Broadcom MASTERS national competition.

CorrDefense: : I understand there were over 60,000 middle school students who participated in Society for Science and the Public-affiliated fairs across the U.S. last year, and the Broadcom MASTERS is one of those programs. The top 10 percent were nominated for the national Broadcom MASTERS science competition. You were one of the 30 finalists selected to attend Broadcom MASTERS. What were a few of the highlights of your competition week in Washington D.C. with the other finalists?

Working in The University of Akron Corrosion Lab in October 2011, Lisa Criscione pours a saltwater solution (electrolyte) into the container until the water touches the concrete sample. Also pictured is the corrosion cell used to accelerate corrosion. Photo by Freda Criscione.


Lisa Criscione: It was very interesting—I experienced the transition from being a top student in my science class to being one of many smart people who have the same interests as me. We all became instant friends. Besides the individual poster session competition, we competed in nine team challenge activities â€“ one for each of the STEM (Science, Technology, Engineering, and Math) areas. In one challenge, we had to research the problems involved in fracking and why it's such an important environmental safety issue. In another challenge activity we got to build a house out of Popsicle sticks but it had to be built to survive a hurricane. We had to use the materials available to us, and we couldn't exceed our budget. Even though my team didn't win the STEM challenges, I did end up having an asteroid named after me. How many kids can say that?

CorrDefense: I understand that you took first place in Chemistry at the Northeast Ohio Science and Engineering Fair, where you spoke with 15 judges. Tell us about your experience talking to the judges.

Lisa Criscione: At first I was really nervous. I double-checked my notes every chance I got. Once I realized that my judges weren't going to grill me alive, I grew more relaxed. I had intelligent conversations with the judges about real-life applications of my project and answered every question they threw at me. One judge wanted to know where cement came from and how it was made; I talked to her for half an hour on that question alone. Another judge came up and asked me what exactly rust was. Once I gave him my definition, he said, "You just explained that better than any of the college students I teach." That caught me by surprise! Throughout the duration of the fair, I gave a seemingly endless presentation of my project. More and more judges kept coming up to listen to me. I ended up talking for about three hours straight. Only once did I get a ten-minute break!

CorrDefense: When you conceived the idea for the "Rusty Concrete" project, with whom did you work with initially at Incarnate Word Academy?

Lisa Criscione: My science teacher was Mrs. Cynthia Rossman, and she required all of us to do a science fair project in seventh grade. It was optional in eight grade. She gave me a timeline and checklist to follow. Mrs. Rossman reviewed my proposal and made sure I was following the scientific method and using the right reference materials. At Incarnate Word, I was the only student interested in corrosion and civil engineering.

CorrDefense: Given your success over the past year, what new projects and career options are you contemplating?

Lisa Criscione: : I'm doing another science fair project this year involving designing basalt fiber/steel concrete reinforcements. Since my experience in the UA Corrosion Lab, I'm now more focused on science rather than history. I'm thinking about studying corrosion engineering in college. Some day I think it would be nice if I could work in the lab, but I'm more interested in seeing if the products tested in the lab actually work in a real-world situation.

Editor's Note: Between January and May, 2012, Criscione received special awards from five professional associations, including the American Society of Civil Engineers' Ohio Council and Central Ohio Section, the American Chemical Society's Columbus Section, ASM International's Cleveland Chapter, the Cleveland Chemical Association, and ASM International's Akron Chapter.

During the Broadcom MASTERS national event, Lisa Criscione talks with Rich Hays, deputy director of the DoD Corrosion Policy and Oversight Office, which funds programs benefiting students at The University of Akron Corrosion Lab. Photo by IML Photography, SSP.


Volume 8, Number 3 Fall 2012 Inside DoD

DoD Estimates the Annual Cost of Corrosion for Navy Ships

Latest Report Employs Data from Fiscal Years 2008-2010

By Eric Herzberg

LMI Government Consulting was asked by the DoD Corrosion Prevention and Control Integrated Product Team (CPC IPT) in May 2011 to measure the cost of corrosion on U.S. Navy ships. This review is part of a multi-year plan to measure the effects of corrosion on DoD weapon systems. Table 1 lists past and current Navy corrosion studies. (The study period is one calendar year.)

The most recent report, Estimate of the Annual Cost of Corrosion for Navy Ships: FY 2008-2010 Update, was published in September 2012. The report provides an update of previous studies on corrosion-related costs for Navy ships. It also is the first study to include an analysis of the effect of corrosion on availability for Navy ships.

Table 1. Navy Cost-of-Corrosion Studies

Using fiscal year (FY) 20101 as a measurement baseline, we estimated the annual corrosion-related cost for Navy ships to

be $3.15 billion, or 18.7 percent of the total maintenance cost for all Navy ships, $16.6 billion.2

The increase in corrosion-related costs between FY2008 and FY2010 was the result of both an increase in maintenance labor costs

3 and an increase in corrosion-related costs attributable to commercial depot maintenance.


1LMI based the Navy's corrosion-related costs on FY2010 data, the most recent year for which study data was available.

2We calculated the total Navy ships maintenance cost by aggregating depot and field-level maintenance and select costs outside normal maintenance

reporting. 3The FY2010 labor rates were 5.7 percent and 7.7 percent higher than the FY2008 labor rates for military and civilian maintenance technicians,

respectively.

We segregated the corrosion-related costs using three schemas: 1) depot or field-level maintenance (DM or FLM) costs, as well as costs outside normal maintenance reporting (ONR); 2) corrective versus preventive maintenance costs; and 3) costs related to structure or parts.

Table 2 shows both the costs and percentages within each schema for FY2010.

Table 2. Nature of Corrosion-Related Costs for Navy Ships (FY2010)

The Navy incurs the highest corrosion-related costs during depot maintenance ($1.52 billion), which represents a little less than half of the total corrosion-related costs for Navy ships. Also of note is the percentage of corrosion-related DM costs compared to the total DM costs (roughly 20 percent of $7.61 billion) and corrosion-related FLM costs compared to the total FLM costs for ships (roughly 16 percent of $6.52 billion). The corrosion-related ONR cost ($619 million) for Navy ships is relatively high in relation to other military services. This is due to the large population of shipboard personnel who perform corrosion-related maintenance, even though their skill specialty is not associated with maintenance. The amount of corrosion-related maintenance performed by non-maintenance shipboard personnel has increased significantly since the initial FY2004 study, when it was $314 million.

Table 3 shows the corrective and preventive corrosion-related costs over the years (FY2004 and FY2008—10).


Table 3. Navy Ships Corrective and Preventive Corrosion-Related Cost by Study Year

Costs incurred to prevent corrosion (e.g., painting, inspection, coating, and quality assurance) increased by more than $360 million from FY2004 to FY2010. Corrosion-related corrective costs decreased slightly during the same period.

We also segregated corrosion-related costs according to ship category. Table 4 presents a summary of these costs. We accounted for a total of 237 ships across all ship categories and all three fiscal years. The corrosion-related costs for surface warfare ships and carriers increased between FY2008 and FY2010, while the per-ship average for amphibious ships and submarines remained fairly stable.

Table 4. Corrosion-Related Maintenance Cost by Ship Category (in millions)

Table 5 and Table 6 show the top five corrosion-related costs by work breakdown structure for ships and submarines, respectively. The work breakdown structure (WBS) allows us to determine the major systems and subsystems incurring maintenance. The two highest corrosion-related WBS cost categories for surface ships and submarines are the same: 1) trunks and enclosures and 2) painting. The corrosion-related costs for submarines are more concentrated by WBS than the corrosion-related costs for surface ships. (Note: Percentages are not exact due to rounding. ESWBS = expanded ships work breakdown structure. This is the work breakdown structure schema used for Navy surface ships.)


Table 5. Navy Surface Ships Corrosion-Related Cost Ranking by ESWBS for FY2010

Table 6. Navy Submarines Corrosion-Related Cost Ranking by SWLIN for FY2010

Navy ships are nearly always able to put out to sea when required. What non-availability that does occur happens during the performance of depot maintenance at a Navy (organic) or commercially operated shipyard.

We determined that corrosion-related work accounts for an average of 25 percent of the total DM dry-dock work performed during dry-dock periods. Although not a precise correlation, if the average DM period is 155 days, we can infer that corrosion-related work contributes to about 38 days of the non-availability for each Navy ship in depot maintenance during a dry-dock period.



Cadets Honored by Headquarters U.S. Air Force for Material Degradation Research


U.S. Air Force Academy (USAFA) cadets continue to make inroads into the field of materials degradation research, under the auspices of a program overseen by a premier university laboratory, the USAFA Department of Engineering Mechanics Center for Aircraft Structural Life Extension (CAStLE).

Brigadier General Dana Born, Dean of the Faculty at USAFA, added her congratulations to CAStLE's team of six cadets after they won the 2012 U.S. Air Force Science, Technology, Engineering, and Mathematics (STEM) Cadet Team award.

The cadets' multi-disciplinary research project formed part of a larger CAStLE research program sponsored by the Office of the Secretary of Defense Corrosion Policy and Oversight Office. Specifically, the research project investigated the effect of a particular type of bacteria on slowing crack growth in a commonly used aircraft aluminum. The bacteria are common in both highly clean and hostile environments and their presence has been observed to slow fatigue crack growth. The award, titled, "The Effect of Bacteria on Corrosion Fatigue in 7xxx Series Aluminum Alloys," was the culmination of a one-year

cadet project.

"This cadet project is a vital element of the larger, ongoing CAStLE program that seeks to quantify and predict the impact of environmental degradation on crack growth and structural integrity," noted Gregory Shoales, CAStLE director.

Headquarters United States Air Force presented the award during an August 23, 2012, ceremony at Wright Patterson Air Force Base. Recipients from the USAFA's Engineering Mechanics department included Ben Hoff, Dan Henning, and Sarah Collins. Winners from the Biology department included Tim Reid, Ryan Young, and Henry Binzer. Besides Shoales, CAStLE representatives who accompanied the cadets included Col. Andy Szmerekovsky, Engineering Mechanics department head; and Sarah Galyon Dorman, CAStLE support contractor from SAFE, Inc.

"Ms. Galyon Dorman was the mentor for this project, and she continues to successfully oversee multiple ongoing cadet projects in the field of corrosion and material degradation," said Shoales.

Mentor Galyon Dorman (second from left) joins U.S. Air Force

Academy cadets Ben Hoff, Sarah Collins, and Tim Reid as they

accept a team award from the Headquarters United States Air

Force for material degradation research on behalf of six cadets

from the Engineering Mechanics and Biology departments.

Photo courtesy of U.S. Air Force Academy/CAStLE (Center for

Aircraft Structural Life Extension.)

________________________________

Page 1 © 2005-2012 CorrDefense Online Magazine


CorrSim Computer Game Takes Top Honors in 2012

From Your Desktop or Mobile Device, Play CorrSim Online or Via Facebook!


A DoD-sponsored computer simulation game that allows users to learn the basics of corrosion engineering continues to attract attention among technical and industry experts.

Since the game's debut in August 2011, CorrSimulator, or CorrSim has garnered top honors from the National Training Systems Association (NTSA) and NACE International, The Corrosion Society, both of whom recognize the value of computer simulation games produced by the U.S. government. In October 2012, NTSA selected

CorrSim as a finalist in the "Government" and "Adaptive Force" categories in its Serious Games Showcase & Challenge competition.

CorrSim is a single-player, turn-based simulation game designed to teach students the environmental factors that cause corrosion on man-made structures, how to protect the structures, and the consequences of corrosion on the economy. Designed for all ages and professional levels, CorrSim players are challenged to build an industrial complex and protect it from corrosion using a menu of combating technologies. During the game, players can optimize their earnings and use their money to build more structures.

GSG Systems and Bruno White Entertainment produced CorrSim for the DoD Corrosion Policy and Oversight Office and a vast network of corrosion science experts in the military and industry.

The CorrSim app is designed for Facebook and the iPad, as well as other mobile devices.

"The challenge for the CorrSim player is to be as proactive as possible, since some random events can either move the player ahead, or erase all of his or her efforts," said Daniel J. Dunmire, director of the Corrosion Policy and Oversight Office.

On March 12, 2012, NACE International granted the CorrSim app the "MP Readers' Choice Innovation of the Year Award" in the "Corrosion Protection" category.

Producers of CorrSim will have an opportunity to showcase its features during the final NTSA competition from December 3-6, 2012, at the Inter-service/Industry Training Simulation and Education Conference in Orlando, Florida.

http://corrdefense.nace.org/corrdefense_summer_2012/DoD_3.asp

http://corrdefense.nace.org/corrdefense_summer_2012/DoD_3.asp



Course Funding Available for Military Corrosion Specialists

By Cynthia Greenwood and Earl Wingrove

Besides the immense array of new educational podcasts and videos that are online or in production, DoD personnel and civilian contractors are encouraged to take advantage of training courses in the field of corrosion prevention and mitigation. A host of opportunities exist through technical societies such as NACE International—The Corrosion Society, and SSPC—The Society for Protective Coatings. Technicians, inspectors, engineers, consultants, architects, and project managers may take advantage of a diverse array of courses related to Basic Corrosion, Cathodic Protection, Corrosion Assessment, Coatings, Coatings Inspection, and Water/Wastewater Facilities. Descriptions of the most popular course offerings are listed below, according to the subject area of expertise. To learn more about course schedules, content, and individual training providers, please click on a course title and you will be linked to the appropriate Web site and course description. To view all 34 DoD-funded courses sponsored by SSPC, please view the following list of courses on the SSPC Web site.

General Corrosion Education Basic Corrosion Basic Corrosion This course focuses on corrosion and the potential problems caused by corrosion. It provides a basic but thorough review of the causes of corrosion and the methods by which it can be identified, monitored, and controlled. Active participation is encouraged through hands-on experiments and case studies, as well as an open discussion format.

Cathodic Protection CP-1 Cathodic Protection Tester Course This is an intensive six-day course that presents CP technology to prepare students for the NACE Cathodic Protection Tester Certification Examination. Course topics include basic electricity, electrochemistry and corrosion concepts, CP theory, CP systems, and CP field measurement techniques. This course provides theoretical knowledge and practical fundamentals for testing on both galvanic and impressed-current CP systems. It also involves lectures and intensive hands-on training with equipment and instruments used in CP testing. Hands-on training at outdoor facilities (weather permitting) is also provided. The course concludes with both a two-hour written and a two-hour practical (hands-on) examination. CP-2 Cathodic Protection Technician This is an intensive six-day course that presents CP technology to prepare students for the NACE Cathodic Protection Technician Certification Examination. Course topics include intermediate-level discussions of corrosion theory and CP concepts, types of CP systems, stray alternating-current and direct-current interference, and advanced field-measurement techniques. This course provides both theoretical knowledge and practical techniques for testing and evaluating data to determine the effectiveness of both galvanic and impressed current CP systems and to gather design data. The course involves lectures and hands-on training with equipment and instruments used in CP testing. Hands-on training at outdoor facilities is also included, weather permitting.

Course Listings

• Basic Corrosion

• Cathodic Protection

• Coatings and Coatings Inspection

• Internal Corrosion Courses

http://www.sspc.org/Free-Funding

http://www.nace.org/cstm/education/Program.aspx?id=403af18b-d51c-db11-953d-001438c08dca

http://www.nace.org/cstm/education/Program.aspx?id=403af18b-d51c-db11-953d-001438c08dca

http://www.nace.org/cstm/education/Program.aspx?id=2ce9ffdb-8816-db11-953d-001438c08dca




http://corrdefense.nace.org/corrdefense_fall_2012/DoD_4.asp#Basic

http://corrdefense.nace.org/corrdefense_fall_2012/DoD_4.asp#CathodicProtection

http://corrdefense.nace.org/corrdefense_fall_2012/DoD_4.asp#CoatingsandCoatingsInspection

http://corrdefense.nace.org/corrdefense_fall_2012/DoD_4.asp#CoatingsandCoatingsInspection

http://corrdefense.nace.org/corrdefense_fall_2012/DoD_4.asp#Internal


CP-2 Cathodic Protection Technician-Marine Developed for NAVSEA (Naval Sea Systems Command), this six-day course provides theoretical knowledge and practical techniques for testing and evaluating data to determine the effectiveness of both galvanic and impressed current CP systems, as they apply to the marine industry. This is an intermediate CP course. CP-3 Cathodic Protection Technologist This is an intensive six-day course that presents CP technology to prepare students for the NACE Cathodic Protection Technologist Certification Examination. The CP 3—Cathodic Protection Technologist Course builds on the technology presented in the CP 2—Cathodic Protection Technician Course covering both theoretical concepts and practical application of CP, with a strong focus on interpretation of CP data, CP troubleshooting, and mitigation of problems that might arise in both galvanic and impressed current systems. The course is presented in a format of lecture, discussion, and hands-on, in-class experiments, and group exercises. There is a written examination at the conclusion of the course. CP-4 Cathodic Protection Specialist This is an intensive six-day course that focuses on the principles and procedures for CP design on a variety of structures for both galvanic and impressed current systems. The course discusses the theoretical concepts behind the design and considerations that influence the design (environment, structure type/materials of construction, coatings), design factors, and calculations (including attenuation). The course involves lecture and in-class discussion and practice with design examples on various structures (i.e., pipelines, tanks and well casings, offshore applications, and steel reinforcing in concrete structures). The course concludes with the written NACE CP Specialist examination. CP Interference The Cathodic Protection Interference course is a six-day course focusing on AC and DC interference. The course includes in-depth coverage of both the theoretical concepts and the practical application of identifying interference and interference mitigation techniques. Students will learn to identify the causes and effects of interference as well as conduct tests to determine if an interference condition exists and perform calculations required to predict AC interference. The course is presented in a format of lecture, discussion, hands-on, in-class experiments, case studies, and group exercises. There is a written examination at the conclusion of the course. Offshore Corrosion Assessment Training (O-CAT) The Offshore Corrosion Assessment Training course is a five-day intensive program addressing the elements of in-service inspection and maintenance planning for fixed offshore structures. The course also addresses the Minerals Management Services (MMS) A-B-C facility evaluation grading-system requirements for Level I inspection reporting.

Coatings and Coatings Inspection C-1 Fundamentals of Protective Coatings for Industrial Structures This course provides a practical and comprehensive overview for those who are new to the protective coatings industry. It is also an ideal refresher for reviewing the fundamentals of corrosion and the use of coatings as a protective mechanism against corrosion and deterioration of industrial structures. C-1 eCourse Fundamentals of Protective Coatings for Industrial Structures This online course provides a practical and comprehensive overview for individuals who are new to the protective coatings industry, as well as those needing a review of the fundamentals of corrosion and the use of coatings as a protective mechanism. It begins on the 15th of every month. C-2 Specifying and Managing Protective Coatings Projects This course is designed to sharpen your skills in managing the specific requirements of protective coatings projects. C-2 eCourse Specifying and Managing Protective Coatings Projects This online management course is designed to sharpen your understanding of overall industry practices, beyond your area of specialization, and put your experience in unison with the most current theories and practices that govern coatings project management. It begins on the 15th of every month in 2009. C-7 Abrasive Blasting Program C-7 is designed to certify operators of dry abrasive or portable centrifugal blast cleaning equipment. It covers principles of surface preparation, surface cleanliness, surface profile, dust and debris control, and abrasives. The program’s primary focus is the certification of the blasters who demonstrate proper blasting techniques during the hands-on session. CCI Concrete Coating Inspector Program Students who take this course will be able to determine incompleteness and/or technical errors in a specification and bring these issues to the attention of the specification writer or a supervisor. The course also reviews how to use concrete coating inspection equipment according to the manufacturer’s guidelines. The certification portion of this program will certify concrete coating inspectors in the process of correctly observing, assessing, documenting, and reporting all relevant job data as determined by the specification and referenced documents. Students completing the technician-level training (first four days only) would be qualified to work under the guidance of a certified concrete coating inspector.









http://www.nace.org/cstm/education/Program.aspx?id=f017dc9e-4853-dd11-889d-0017a446694e


http://www.sspc.org/Fundamentals-of-Protective-Coatings-C1/

http://www.sspc.org/Fundamentals-of-Protective-Coatings-C1/

http://www.sspc.org/Fundamentals-of-Protective-Coatings-C1-eCourse/

http://www.sspc.org/Fundamentals-of-Protective-Coatings-C1-eCourse/

http://www.sspc.org/Planning-and-Specifying-Industrial-Coatings-Projects-C2/

http://www.sspc.org/Planning-and-Specifying-Industrial-Coatings-Projects-C2/

http://www.sspc.org/Planning-and-Specifying-Industrial-Coatings-Projects-C2-eCourse/

http://www.sspc.org/Planning-and-Specifying-Industrial-Coatings-Projects-C2-eCourse/

http://www.sspc.org/Abrasive-Blasting-Program-C7/

http://www.sspc.org/Abrasive-Blasting-Program-C7/

http://www.sspc.org/concrete-coating-inspector-cci-program-levels-and-options/

http://www.sspc.org/concrete-coating-inspector-cci-program-levels-and-options/


C-12 Airless Spray Basics This course is designed to train marine/industrial applicators to operate airless spray equipment, incorporating the use of a paint simulator for hands-on training. You'll learn the proper technique for airless spray painting by using a program that simulates real life situations and equipment used in the field. There are two course options that allow participants to complete training and certification that meet NAVSEA 009-32 requirements. Click on the link above for details about each course offering. C-14 MPCAC - Marine Plural Component Program This course is designed to certify craft workers operating plural component spray equipment. It also certifies those applying protective coatings on steel in immersion service by airless spray using plural component spray equipment. Lead Paint Removal (C3) C3 includes background information on the hazards of lead and other toxic metals as well as the current legal and regulatory environment. The course contains specific discussions on protecting workers; compliance with environmental regulations; proper management of waste streams and operations that result in potential exposures to lead; and associated control technology. The course also addresses reading specifications and developing programs to effectively control risks to workers, the public, and the environment. It concludes with a discussion of insurance and bonding issues, and an introduction to other safety and health issues that are encountered on painting projects. Navigating Standard Item 009-32 This one-day course describes the naval ship cleaning and painting requirements found in Standard Item 009-32. It covers the cleanliness, surface preparation, coating application requirements, and system application instructions for various Navy vessels. Requirements of referenced standards are also reviewed. Quality Control Supervisor (QCS) This course is designed to provide training in quality management for SSPC - Certified contractor personnel, Technical Quality Managers (TQM), and inspectors employed by SSPC-QP 5 inspection firms. It provides an overview of the quality management aspects of surface preparation, paint, coatings, and inspection operations that a Quality Control Supervisor (QCS) needs to know to ensure delivery of a quality product to customers. It is highly recommended that persons attending the QCS course have recent inspection training (SSPC PCI, NBPI or BCI ) or equivalent formal training, and also some quality-control experience. Quality Control Supervisor (QCS) eCourse This course is designed to provide training in quality management for SSPC - Certified contractor personnel, Technical Quality Managers (TQM), and inspectors employed by SSPC-QP 5 inspection firms. It provides an overview of the quality management aspects of surface preparation, paint, coatings, and inspection operations that a Quality Control Supervisor (QCS) needs to know to ensure delivery of a quality product to customers. Basics of Steel Surface Preparation eCourse This course defines surface preparation for steel through a brief review of the steps involved. It then provides an overview of abrasive blast cleaning, hand-and-power-tool cleaning, and water jetting and the associated standards referenced when these methods are used to prepare steel for the application of protective coatings. Coating Inspector Program (CIP) Level 1 This course is an intensive presentation of the basic technology of coating application and inspection over a full 60 hours of personal instruction and practice. This course provides both the technical and practical fundamentals for coating inspection work on structural steel projects. Coating Inspector Program (CIP) Level 2 This course focuses on advanced inspection techniques and specialized application for both steel and non-steel substrates. The course includes in-depth coverage of surface preparation, coating types, inspection criteria, and failure modes for various coatings, including specialized coatings and linings. Coating Inspector Program (CIP) Level 2 Marine CIP Level 2, maritime emphasis, includes topics from CIP Level 1 and CIP Level 2, with a focus on coating inspection in the maritime industry. The course provides in-depth coverage of surface preparation, coating types, inspection criteria, failure modes, and case studies from the maritime industry. CIP Level 2, maritime emphasis, highlights the skills and knowledge required to correctly address the inspection requirements of the International Maritime Organization’s (IMO’s) Performance Standard for Protective Coatings (PSPC). The course concludes with both written and practical exams. Coating Inspector Program (CIP) Level 3 Peer Review This course is a detailed oral examination in front of a three-member review board that lasts approximately two hours and is graded on a pass/fail basis. The Peer Review includes a series of questions to test the candidate’s practical and theoretical knowledge of coatings and coating inspection. Candidates are questioned from a random drawing of topics ranging from standards, procedures, ethics, coatings use, inspection instruments, role-playing, and specific case questions. Successful completion of the CIP Peer Review is required to achieve recognition as a NACE Certified Coating Inspector Level 3 individual.

http://www.sspc.org/Airless-Spray-Basics-C12/

http://www.sspc.org/Airless-Spray-Basics-C12/

http://www.sspc.org/Marine-Plural-Component-Program-MPCAC-C14/

http://www.sspc.org/Marine-Plural-Component-Program-MPCAC-C14/

http://www.sspc.org/Lead-Paint-Removal-C3/

http://www.sspc.org/Lead-Paint-Removal-C3/

http://www.sspc.org/Navigating-Standard-Item-009-32/

http://www.sspc.org/Navigating-Standard-Item-009-32/

http://www.sspc.org/Quality-Control-Supervisor-QCS/

http://www.sspc.org/Quality-Control-Supervisor-QCS/

http://www.sspc.org/Quality-Control-Supervisor-QCS-eCourse/

http://www.sspc.org/Quality-Control-Supervisor-QCS-eCourse/

http://www.sspc.org/Basics-of-Steel-Surface-Preparation-eCourse/

http://www.sspc.org/Basics-of-Steel-Surface-Preparation-eCourse/

http://www.nace.org/cstm/education/Program.aspx?id=dcf75ff6-8816-db11-953d-001438c08dca









C-14 MPCAC - Marine Plural Component Program This course is designed to certify craft workers operating plural component spray equipment. It also certifies those applying protective coatings on steel in immersion service by airless spray using plural component spray equipment. NBPI—NAVSEA Basic Paint Inspector Course The NBPI course is similar to NACE Level I or SSPC C-1, but it was developed by the Navy. This four-day quality assessment course was developed by NAVSEA (Naval Sea Systems Command) to train coating inspectors to inspect critical coated areas as defined by Navy policy documents. These areas include but are not limited to cofferdams, decks for aviation and underway replenishment, chain lockers, underwater hulls, bilges, tanks, voids, well deck overheads, and others. The content of the course is similar in nature to the NACE CIP Level I, but with a particular focus on ship-painting issues. What makes this course valuable is that it also provides both the technical and practical fundamentals for coating inspection work for any steel structure projects other than ships. Protective Coatings Inspector Program (PCI) PCI Level 2 meets ASTM International Standard D3276, “Standard Guide for Painting Inspectors,“ and has been approved by Lloyd’s Register, RINA, and the American Bureau of Shipping (ABS). The objective of this course is to thoroughly train individuals in the proper methods of inspecting surface preparation and installation of industrial and marine protective coatings and lining systems on an array of industrial structures and facilities. There are no prerequisites to attend the PCI Course. However, this course is not an entry-level course. Shipboard Corrosion Assessment Training (S-CAT) In this five-day course developed for naval personnel, students learn how to survey and evaluate protective coating systems as part of a maintenance program for marine vessels. This course is intended to provide a foundation in coatings, corrosion, and corrosion control knowledge for assessing the condition of tanks and other structures, and determining the required actions necessary to effectively maintain fully operational status. The course will equip the assessor with practical guidelines for surveying and evaluating the condition of the protective coating system on specific areas of a marine vessel. The desired end result is that assessors use a consistent, orderly, and repeatable process of evaluation that has the confidence of all those involved in the maintenance cycle.

Internal Corrosion Courses Internal Corrosion (IC) for Pipelines: Basic This course was designed to provide students with the fundamentals of implementing, monitoring, and maintaining an internal corrosion control program as part of an overall Pipeline Integrity Management program. It is an introductory-level course focusing on the internal corrosion of liquid and natural gas pipelines used for transmissions, storage, and gathering systems. The course combines lecture, hands-on field-testing, and case studies. The course concludes with both a written and practical examination. The practical examination includes Operator Qualification Covered Task Assessments for the following tasks: (1) Insert and remove internal corrosion coupons, (2) Measurement of corroded area and pit depth measurement (with pit gauge), (3) Measure wall thickness using handheld ultrasonic meter. Internal Corrosion (IC) for Pipelines: Advanced The Advanced Internal Corrosion for Pipelines course focuses on the monitoring techniques and mitigation strategies required to assess internal corrosion and develop and manage internal corrosion control programs. Data interpretation, analysis and integration, as well as criteria for determining corrective action for high-level internal corrosion problems within a pipeline system, will be covered in detail. The course will be five days in length. Students successfully completing the course examination and who also meet the requirements can apply for certification as a Senior Internal Corrosion Technologist.

For more information about the organizations that provide training for DoD employees, please consult the following Web sites: • NACE International—The Corrosion Society • SSPC—The Society for Protective Coatings

http://www.sspc.org/training/mpcac.html

http://www.sspc.org/training/mpcac.html

http://www.sspc.org/navsea-basic-paint-inspector-nbpi/

http://www.sspc.org/navsea-basic-paint-inspector-nbpi/

http://www.sspc.org/Protective-Coatings-Inspector-Program-PCI/

http://www.sspc.org/Protective-Coatings-Inspector-Program-PCI/



http://www.nace.org/cstm/education/Program.aspx?id=073c976d-b51d-db11-953d-001438c08dca




http://www.nace.org/

http://www.sspc.org/


Volume 8, Number 3 Fall 2012 through Spring 2013 Conferences

DECEMBER

Defense Logistics 2012 December 3-5, 2012 Arlington, Virginia http://www.wbresearch.com/defenselogisticsusa

International Conference on Corrosion Mitigation and Surface Protection Technologies The Egyptian Corrosion Society December 10-13, 2012 Hurghada, Egypt http://www.egy-corr.org/30conf2012/confindex.htm

JANUARY

AUSA's ILW Army Aviation Symposium & Exhibition January 9-11, 2013 National Harbor, Maryland http://www.ausa.org/meetings/2013/Symposia/AviationSymposium/Pages/AviationHome.aspx

SSPC 2013 January 14-17, 2013 San Antonio, Texas http://www.sspc.org/sspc-events/events-home/?id=2

FEBRUARY

Marine West Military Expo 2013 February 13-14, 2013 Marine Corps Base, Camp Pendleton, California http://www.marinemilitaryexpos.com/marine-west.shtml

AUSA's ILW Winter Symposium and Exposition Association of the United States Army

http://www.wbresearch.com/defenselogisticsusa

http://www.wbresearch.com/defenselogisticsusa

http://www.egy-corr.org/30conf2012/confindex.htm

http://www.egy-corr.org/30conf2012/confindex.htm

http://www.ausa.org/meetings/2013/Symposia/AviationSymposium/Pages/AviationHome.aspx

http://www.ausa.org/meetings/2013/Symposia/AviationSymposium/Pages/AviationHome.aspx

http://www.sspc.org/sspc-events/events-home/?id=2

http://www.sspc.org/sspc-events/events-home/?id=2

http://www.marinemilitaryexpos.com/marine-west.shtml

http://www.marinemilitaryexpos.com/marine-west.shtml


February 20-22, 2013 Fort Lauderdale, Florida http://www.ausa.org/meetings/2013/Symposia/WinterSymposium/Pages/2013WinterSymposium.aspx

MARCH

2013 IEEE Aerospace Conference March 2-9, 2013 Big Sky, Montana http://www.aeroconf.org

CORROSION 2013-NACE International March 17-21, 2013 Orlando, Florida http://www.nacecorrosion.org

GOMACTech 2013 Government Microcircuit Applications & Critical Technology Conference March 11-14, 2013 Las Vegas, Nevada http://www.gomactech.net

Measurement Science Conference March 19-23, 2013 Anaheim, California http://www.msc-conf.com/conference-location

APRIL

AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics and Materials Conference April 8-11, 2013 Boston, Massachusetts https://www.aiaa.org/EventDetail.aspx?id=4708

http://www.ausa.org/meetings/2013/Symposia/WinterSymposium/Pages/2013WinterSymposium.aspx

http://www.ausa.org/meetings/2013/Symposia/WinterSymposium/Pages/2013WinterSymposium.aspx

http://www.aeroconf.org/

http://www.aeroconf.org/

http://www.nacecorrosion.org/

http://www.nacecorrosion.org/

http://www.gomactech.net/

http://www.gomactech.net/

http://www.msc-conf.com/conference-location

http://www.msc-conf.com/conference-location

https://www.aiaa.org/EventDetail.aspx?id=4708

Survey Furthers Development of Corrosion Software...

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