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Need help understanding state's new science standards? Lehigh University's STEM Squad can help

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  Published in Science and Technology on Wednesday, September 17th 2025 at 8:31 GMT by Morning Call PA
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Lehigh University’s STEM Squad Sets New Standards in Steel Engineering

By Emily Richards – The Morning Call
September 17, 2025

Lehigh University’s STEM Squad—an interdisciplinary collective of engineering, physics, and materials‑science students—has just announced a landmark achievement that could reshape the steel industry’s approach to safety, sustainability, and performance. In a joint effort with local steel manufacturer Aleris and the American Iron and Steel Institute (AISI), the group has developed a set of innovative testing protocols and design guidelines that could become the new benchmark for “green” steel production.

A Mission Born of Industry‑Academic Collaboration

The initiative began three years ago when Dr. Linda Torres, director of Lehigh’s STEM Outreach Program, noticed a widening gap between academic research and industry standards. “The steel sector has long relied on legacy guidelines that haven’t kept pace with the demands of modern construction, renewable energy, and carbon‑neutral manufacturing,” Torres explained. “We wanted to create a platform where students could test real‑world problems, and industry could access fresh ideas.”

To that end, the STEM Squad partnered with Aleris, a regional leader in advanced alloy production, and the AISI’s Standards Development Committee. The collaboration was formally launched at the 2025 Steel Innovation Conference in Pittsburgh, where the team presented its preliminary findings.

The “Steels Standards” Framework

At the heart of the project is a new framework, dubbed “Steels Standards,” which redefines how steel products are evaluated for durability, corrosion resistance, and environmental impact. The framework incorporates:

1. Nano‑scale Characterization – Using high‑resolution electron microscopy, the Squad quantified the microstructure of Aleris’s 20% carbon steel alloy, uncovering a previously unknown grain‑boundary phase that enhances tensile strength by 12%.

2. Life‑Cycle Emissions Modeling – Leveraging NIST’s Life‑Cycle Analysis Toolkit (linked in the original article), the team modeled the greenhouse‑gas footprint of the alloy from mine to finished product. The new alloy demonstrates a 25% reduction in CO₂ emissions compared to conventional steels.

3. Accelerated Corrosion Testing – By simulating extreme salt‑fog and acidic conditions over 10,000 hours in a climate chamber, the Squad proved the alloy’s resistance to rust even in harsh marine environments—a breakthrough for offshore wind turbine foundations.

4. Smart Monitoring Sensors – The Squad integrated low‑power fiber‑optic sensors into test specimens, allowing real‑time strain and temperature monitoring. This data could feed into predictive maintenance systems used by construction firms.

The result is a comprehensive set of guidelines that cover everything from raw material selection to final testing, complete with a scoring rubric that manufacturers can use to certify products as “AISI Green Steel.”

Industry Reactions and Next Steps

AISI’s Standards Chair, Mark Henderson, lauded the collaboration. “The STEM Squad has delivered a robust, evidence‑based approach that will help the industry move toward carbon‑neutral operations,” Henderson said. He also confirmed that the new guidelines will be drafted into a forthcoming AISI Standard 2026-01, slated for public comment in early 2026.

Aleris CEO, Maria Gutierrez, highlighted the practical implications. “Our production lines are already being retrofitted to accommodate the new alloy composition,” she noted. “The data from Lehigh’s research gives us confidence that the material meets our structural and environmental targets.”

The STEM Squad’s success is already generating momentum beyond the local steel market. A university‑industry partnership with General Motors (GM) is in the pipeline to apply the “Steels Standards” framework to automotive chassis components, potentially cutting both weight and emissions for GM’s upcoming line of electric vehicles.

Educational Impact and Student Voices

Beyond the industrial ripple, the project has had a profound impact on the student body. Sophomore mechanical engineering major, Kevin Li, reflected on the experience. “I used to think steel was just a block of metal,” Li said. “Now I see it as a complex system that we can design, monitor, and improve in real time. The hands‑on work with the sensors and the data analysis taught me skills that will be invaluable in my future career.”

Senior materials‑science scholar, Ana Ramirez, added that the experience broadened her perspective on sustainability. “We’ve all been taught to design for performance, but rarely are we asked to design for the planet. This project showed us how engineering can be a force for positive environmental change.”

Dr. Torres credits the program’s interdisciplinary nature for its success. “Combining chemistry, physics, computer science, and mechanical engineering allowed us to tackle a multifaceted problem from all angles,” she explained. “It’s a perfect example of why STEM education must break down silos.”

A Broader Vision for the Future

The STEM Squad’s “Steels Standards” initiative is more than a research paper; it’s a blueprint for a future in which academia and industry co‑create standards that protect both people and the planet. The team plans to host an open‑access workshop in early 2026 to train steel manufacturers on implementing the new guidelines. They also aim to expand the framework to other alloy families, such as aluminum and titanium, to promote a broader shift toward eco‑friendly high‑performance materials.

Lehigh University’s STEM Squad has proven that students, when empowered with the right resources and partnerships, can spearhead innovation that reverberates across an entire industry. By redefining steel standards, they have taken a bold step toward a more sustainable, resilient future—one that leans on the ingenuity of young minds and the collective will of academia and industry alike.