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Expert in Corrosion, Metallurgy, Metal Surface Treatments, Failure Analysis, and Material Selection
Available for your Consulting and Expert Witness Needs
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Summary of Expertise:
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Listed with other top experts in: |
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For the past 15 years, Expert has been a consultant to the consumer products industries on corrosion and material degradation. He has provided advice on the proper choice of materials, both metallic and non-metallic, as well as the proper procedures for buying and maintaining process equipment. He is experienced with stainless steel laboratory equipment, polymerization equipment, sprinkler systems, reverse osmosis equipment, and corrosion in pipelines and hydraulic systems. He has worked with stainless steel in soil, Inconel 625 corrosion in chloride salts, FRP in scrubbers, PVC and CPVC pipe failures, polycarbonate fatigue, boiler tube wastage, and stainless steel evaporation equipment.
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Another large share of Expert's career has been devoted to materials testing. Both standard and (self-developed) performance tests of materials for wear, corrosion and fatigue are a continuing part of his consultant work. Laboratory simulations of process conditions, via flow loops, cyclic exposures and staged testing have all been used to confirm failure modes and evaluate recommended "fixes". One such application, involving the performance of thermal spray coatings on paper machine-yankee dryers, identified damage from inconspicuous process variables and identified appropriate improvements to coating formulation to overcome the damage. Another example involved staging in fatigue tests for acceleration so that an equitable evaluation of several materials could be achieved within the targeted time for testing. Expert has tested and studied elite corrosion-resistant metals, e.g. tantalum, zirconium, titanium as well as the highly resistant Inconel and Hastelloy alloys in high temperature, brines and pharmaceutical process chemicals. While his studies of MIC originate 25 years ago with electrochemical tests in SRB-laden white water, he recently completed in-mill MIC evaluations of sulfur chemicals, e.g. thiosulfate. Recently, he has also assisted a major chemical company set-up a corrosion laboratory for routine corrosion testing of their products to comply with DOT and in-mill, long-term containment requirements.
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Few materials are inert to all chemicals, but those that come close include tantalum, zirconium, and titanium. Expert has tested and studied the performance of these materials. Additionally, he has studied elite corrosion-resistant metals, including alloy C-276 and Inconel 625. He is knowledgeable of zirconium alloys and tantalum in high chloride (food and pharmaceutical chemicals) as well as titanium and its alloys in biomedical and bleaching environments.
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Expert is knowledgeable of the past and current alloys manufactured for corrosion resistance to specific environments. Alloys that he has tested include duplex stainless steels, ferritic alloys, and the superaustenitics.
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Employing his expertise in corrosion prevention, Expert provided procedures and protocols to continuously monitor corrosion in waste and recycled (closed) water systems. He has consulted with both the chemical and pulp and paper industries regarding the use of redox, pH, corrosion rate meters, and corrosive gas monitors to control volatiles and process chemical corrosion in the waste treatment plant. He has helped municipalities and building owners solve corrosion problems with distribution plumbing, pipes, pumps, and HVAC systems.
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A significant amount of Expert's work has been spent in failure analyses. He has performed failure analyses on corroded items to determine source modes and causes. He has evaluated pipes, pumps, valves, electrical/electronic components, chemical reaction vessels, tanks, mixers, pressure vessels, evaporators, dryers, heat exchangers, boilers, tubes, building facades, fences, hardware, tools, metal coils, and rolls. Under contract with major industries, Expert has performed many failure analyses ranging from boiler tubes to pocket warmers to large complex machinery.
Expert devotes as much of his efforts in finding out "why" in failure analysis to finding out "What to do about it." Sometimes this search of remedy includes in-lab simulations and proof testing as well as performing risk analysis.
Recent failure investigations include plastic and other non-metallic construction materials. PVC, CPVC and other polymeric materials have included environmental stress cracking failure.
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Some of the first fatigue studies Expert conducted were for biomedical implants. Other studies include electrical power plant components, suction roll alloys for the paper industry, and hundreds of other failures by fatigue, including fretting fatigue.
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Since 1975, Expert has used "off-the-shelf" electrochemical corrosion probes and monitoring devices. He performed some of the first studies of their use in the pulp and paper process streams. Using these devices (primarily Petrolite probes and instruments), Expert discovered the changes in corrosivity to brown stock washers with changes in wash water composition, recycled water corrosivity, and limitations of these detection methods in pulping liquor streams. He has hands-on experience with all types of electrochemical devices and coupon corrosion racks or spools. Additionally, he has monitored corrosion in the production of cleaners, shampoos, soaps, soups, coolants, and pharmaceuticals.
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Expert has studied filiform corrosion beneath paint and plated hardware on tool boxes, coated steel panels, jewelry and other consumer products. Recently, he performed studies on lacquered silver artifacts in museums.
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In addition to performing ASTM and NACE standard corrosion rate tests, Expert has used laboratory simulations to test for corrosion by immersion. He has also tested by mixing various water types (conductivities or ionic strengths) with organic compounds and acids (formic, acetic); by vapor exposure; by wetting and drying; and by stressing and exposure. He has evaluated corrosion rate guides, handbooks, and charts, as well as SBIR research proposals and programs to measure corrosion rate in the process industries.
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Expert worked with manufacturers to apply old and new alloys that resist both stress corrosion cracking on the liquid side and cyclic oxidation on the heat side. He is familiar with corrosion issues related to stainless steel food processing vessels, fermenter vessels, heating coils, and ovens. Recently, he helped publish a brochure on stainless steel equipment corrosion for the National Association of Food Equipment Manufacturers (NAFEM).
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Expert has served 14 years as a plant metallurgist in iron and steel foundries. He has written procedures for melting, casting, heat treatment, welding, and inspection of castings for virtually all carbon, low-alloy, and stainless steel grades.
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Employing his expertise in corrosion control, Expert has gained knowledge of electrochemical testing including polarization scans, controlled potential tests, decay (noise), zero resistance ammeter, crevice testing, and galvanic compatibility. He has conducted wet and dry cyclic, wet-dry-wear, and controlled flow-erosion-corrosion tests. He has simulated "worst case scenario" chemical tests. Additionally, Expert is familiar with whisker growth of zinc and silver in accelerated atmospheric corrosion tests.
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Expert has conducted studies of galvanic corrosion of galvanized structures in industrial versus rural environments. A subject of his studies has been atmospheric corrosion of galvanic couples of metals in electrical systems in waste treatment plants. Galvanic corrosion prevention experience also obtained for fire trucks/automotive construction materials, e.g., aluminum, coatings, and nickel-chrome plating.
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Expert's experience in outdoor corrosion has involved building materials corrosion, corten steel corrosion, and corrosion in fences and adjacent structures around swimming pools. He has studied corrosion problems occurring in home gutters and fences, electrical boxes, and in the vicinity of waste treatment plants.
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One of the most persistent problems for all materials, crevice corrosion has been studied for pulp and paper deposits on stainless steels, gasket attack on steel and cast iron pipe/valve flanges, beneath fuel and coolant deposits on steel and aluminum, tube and tube sheet joints in stainless steel heat exchangers, aluminum rivets on aircraft, orthopedic implant metals in bodily fluids, and hardware fasteners of all metal types. Expert has also studied corrosion of stainless steels in acidic chloride blowdown environments for utility companies, intergranular corrosion of stainless steel weldments, liquidation cracking in ferritic stainless steels, and stress corrosion cracking of copper alloys and stainless steels. He is familiar with pitting corrosion of mild steel in organic acids as well as stainless steels in a variety of aqueous environments.
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A significant portion of Expert's career has focused on solving corrosion problems in the pulp and paper industry. He has advised on corrosion issues involving pump impellers, casings, and seals; compactor, calendar, sheeting, and suction rolls; heat exchangers; valves and vacuum pumps; drying equipment; digesters; recovery boilers; clarifiers; and chemical waste treatment equipment. He wrote a chapter in the 1992 TAPPI/CPPA book series on corrosion in pulp and paper manufacture. Expert has direct experience with paints, plating (chromium, nickel, zinc, tin), thermal sprays (molybdenum, nickel-chromium, aluminum), electrolytic and electroless coatings, galvanize, chromates, grease, oil, and vapor phase inhibitors. He can answer questions on rust removal and prevention, galvanizing techniques, and anodic and cathodic protection. Expert has conducted flow loop impingement tests to study erosion corrosion resistance of metals in kraft liquors, food process streams, coolants used in metal fabrication and fiberglass insulation processes, and blow tank target plates for digester emissions.
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Show Secondary and Basic Areas of Expertise | Localities:
Expert may consult nationally and internationally, and is also local to the following cities: Chicago, Illinois;
Rockford, Illinois;
Aurora, Illinois;
Naperville, Illinois;
Peoria, Illinois;
Joliet, Illinois;
Elgin, Illinois;
South Bend, Indiana;
Gary, Indiana;
and Milwaukee, Wisconsin.
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Degree |
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Subject |
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Institution |
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Honors |
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1975
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Ph.D
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Metallurgical Engineering
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Ohio State University
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International Nickel Company Fellow
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M.S.
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Metallurgical Engineering
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University of Wisconsin
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B.S.
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Metallurgical Engineering
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University of Alabama
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| Years |
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Employer |
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Department |
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Title |
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Responsibilities |
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1997 to
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Expert's Firm
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Independent Consultant
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Provide advice to resolve materials-related issues (metallurgy and corrosion). This includes litigation expertise for materials, both metals and non-metals, PVC, CPVC,etc.
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1994 to 1997
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Packer Engineering, Inc.
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Materials - Metallurgical Engineering
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Director of Materials Engineering
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Perform materials corrosion research and testing. Industry inspections and failure analyses.
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1984 to 1994
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Packer Engineering, Inc.
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Metallurgical Division
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Manager Corrosion Engineering
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Corrosion-related investigations and testing for the paper and chemical industries.
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1976 to 1984
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Institute of Paper Chemistry
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Engineering Materials and Corrosion
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Senior Research Associate and Assistant Professor
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Lead corrosion control and research for all pulp and papermaking processes. Establish and teach corrosion in paper industry short couse. Teach two graduate-level courses about electrochemistry and corrosion engineering.
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1959 to 1970
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Ross Meehan Foundry& Dayton Malleable Iron Company
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Iron (Meehanite) & Streel& Columbus Malleable
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Plant Metallurgist
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At Ross Meehan - assisted supervision of melting, welding and heat treatment, via process and quality control. At Dayton Malleable Columbus Ohio, directly supervised iron workers, assisted management with production.
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Associations/Societies
NACE, International,
TAPPI,
ASM, International
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Professional Appointments
Expert has served as Chairman of Central Area NACE International and is a member of Corrosion & Materials Engineering Committee of TAPPI (C&ME). He is Past Chairman of The Chicago Section and North Central Region Chairman of NACE, International. He received the Earl Moorman Award for outstanding leadership from the NACE Chicago Section.
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Awards/Recognition
Expert was awarded an International Nickel Company fellowship to study corrosion and corrosion fatigue of stainless steel. He also received a Foundry Education Foundation fellowship and American Foundrymen's Society assistantships for the study of improved casting quality.
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Publications and Patents Summary
Expert is author or co-author of 25 publications and presentations at major conferences. He is author or co-author of several seminars and training courses about corrosion in the pulp and paper industry.
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Selected Publications and Publishers
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- Studies in Conservation
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- Proceedings of the ASM/TMS/AIME Conference
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- Proceedings National Association of Corrosion Engineers
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- Cyclic Cabinet Corrosion Testing
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- Technical Association of the Pulp and Paper Industry (TAPPI)
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| Selected Consulting Examples: |
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On-site analysis of major corrosion and metallurgy-related problems in paper mills throughout the world from 1976 to the present time.Performed and continues to conduct failure investigations in fire protection sprinkler piping and equipment - both metallic and plastic materials (CPVC, PVC, etc).
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Performed the corrosion investigation of a waste treatment plant, which processed highly corrosive and toxic electronic circuit board, etc. The failure of Inconel 625, Carpenter 20 and other high performance alloys was identified as to mode and cause. Remedial measures were established.
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Fire springler systems from all parts of the USA have been investigated. Research corrosion testing has been formulated to identify failure causes. Both chemical (water) and associated biological conditions as these influence corrosivity continue to be studied.
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Corrosion testing that includes both bench and pilot studies, from soup to adhesives, have been and continue to be performed. The corrosivity of papermaking chemicals toward stainless steels has and continues to be a major effort.
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The on-site investigation of stainless steel equipment for the purpose of maintaining its passivity has been accomplished several times and continues to be done. Novel techniques using hydrogen peroxide and a series of different commercially available passivating agents have been formulated and successfully implemented.
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Recent Client Requests:
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Expert in Corrosion-Material Selection to assist with material tank type selection.
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Steel corrosion expert needed to consult regarding weathering steel plates.
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Galvanic corrosion expert needed for consulting on corrosion inhibitors.
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Steel boiler expert for consulting on cupola liner structure failures.
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Galvanic corrosion expert for consulting on cause of pitting and paint peeling near wheel wells of vehicles.
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Corrosion inhibition expert for consulting on Corrosion Inhibition.
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Corrosion expert, Imlay City, MI for consulting on Clarifier Drive at WWTP.
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Illinois corrosion chemical process expert for consulting on Chemical Process.
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Stainless steel pipe corrosion expert for consulting on Stainless Steel Pipe Corrosion.
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Expert in surface finishing consult for consulting on Aluminum die cast consumer product.
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Expert in Metallurgical and Materials failure analysis for consulting on Stainless Steel Tank Corrosion in Tanks.
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Expert in metallurgical and materials engineering on a corrosion engineering project.
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Passivation expert for consulting on corrosion inhibitor and options for stainless steel (300 and 400 series).
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Expert in consumer products for consulting on converting from 304SS to 202/201SS.
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Expert in paper foil lamination for consulting on filiform corrosion.
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Corrosion expert for consulting on acme screw linear actuator outdoor applications.
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Aluminum corrossion expert for consulting on Corrosion of Exterior Aluminum Skin Building Panels.
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Expert in Rolling mill structure corrosion to consult on corrosion.
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Metallurgist expert for consulting on Dissimilar Metals Analysis of Connector Components.
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Expert for consulting on corrosion of flexible tab circuit issue.
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Corrosion prevention expert for consulting on prevention of aluminum alloys corrosion from chlorinated hydrocarbon solutions and from deionized water.
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Corrosion expert for consulting on aluminum and stainless steel in process air equipment, coastal environment.
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Electrochemistry expert for consulting on high voltage electro chemistry.
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Corrosion metallurgist expert for consulting on corrosion of 304L stainless steel in water treatment service.
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Corrosion expert for consulting on sub sea corrosion of aluminum and stainless steel.
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Passivation expert for consulting on passivation of stainless steel.
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Expert in metals for consulting on understanding corrosion cause of chemical reactor.
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Expert in copper corrosion reduction for consulting on copper corrosion inhibitor for brake fluid.
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Click the green button above to contact
Expert for a free initial screening call regarding your expert consulting needs.
Expert is available for consulting to corporate, legal and government clients.
Remember, your initial screening call to speak with
Expert is free.
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Expert Witness Experience Summary:
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Testified twice in State and Federal Courtrooms. Have been expert for a half a dozen lawfirms on many occasions. The latter work usually stopped at the report and/or deposition level.
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Recent Litigation Client Requests:
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Corrosion expert for consulting on copper pipe stress corrosion cracking.
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Expert in metallurgy for consulting on the conditions and future uses of steel, cold rolled and aluminum coils.
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PVC pipe expert witness for consulting on failure of CPVC pipe in mixed CPVC and steel system.
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Expert in pipe insulation for litigation involving cryogenic piping system that failed.
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Solder manufacturing expert for consulting on solder and flux manufacture.
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Expert in determining the age of a metal fence.
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Click the green button above to contact
Expert for a free initial screening call regarding expert testimony,
litigation consulting and support, forensic services, or any related expert witness services.
A few litigation needs include product liability, personal injury, economic loss, intellectual property
(patent, trademark, trade secret, copyright), and insurance matters. Remember, your initial screening
call to speak with
Expert is free.
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| International Experience: |
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Country / Region |
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Summary |
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1989 to 1989
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Japan
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Worked with major manufacturer of paper machine equipment on corrosion fatique properties of their alloy.
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1992 to 1992
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Hong Kong
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Worked with waste treatment company to fix corrosion problems in new treatment plant.
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1998 to 1998
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India
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Investigation of a failed yankee dryer for an insurance company.
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1984 to 1984
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Sweden/Finland
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Conducted a research project for a paper industry related equipmet and new process company to satisfy the success of corrosion resistance.
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2005 to 2005
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England
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Served as an expert for case involving corrosion and its control for major industrial contractor to Defence Ministry.
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| Language Skills: |
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Description |
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German
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Required learning skill for the Ph.D. degree at The Ohio State University.
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Developed flyers and bulletins for client use in educating employees on the subject of handling and cleaning stainless steel equipment.
Click the green button above to contact
Expert for a free initial screening call regarding your marketing research, industry research, and company
research needs. For research needs involving multiple experts or secondary research,
a Research Director can be assigned to coordinate the work into a custom report for you as a potentially quicker
and more cost effective alternative to doing this work yourself or hiring a boutique consultancy.
Remember, your initial screening call to speak with
Expert is free.
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| Additional Skills and Services: |
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Training/Seminars
Expert has conducted several training seminars on corrosion, materials and metallurgy, corrosion fatigue, and corrosion sensors. Expert wrote the chapter on corrosion in the Pulp and Paper Manufacture, v9 - Mill Control & Control Systems, TAPPI Press, 1989.
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Supplier and Vendor Location and Selection Expert has experience locating vendors of metal suppliers,
surface treatments, plastics and composite materials. He has access to personal contacts, catalogs, handbooks, and the Internet to aid in vendor location.
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Other Skills and Services
Worked to resolve corrosion problems for the National Association of Food Equipment Manufacturers. Resolved major equipment problems for a huge chocolate company and the largest fast food chain.
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Education
