Academic Credentials
  • Ph.D., Materials Science and Engineering, Stanford University, 1977
  • M.S., Materials Science and Engineering, Stanford University, 1974
  • B.S., Mechanical Engineering, University of California, Davis, 1973
Licenses & Certifications
  • Professional Engineer, Arkansas, #16736
  • Professional Engineer Metallurgical, California, #1774
  • Professional Engineer, Michigan, #6201057185
  • Professional Engineer, North Carolina, #037114
  • Professional Engineer Metallurgical, Texas, #118283
  • Professional Engineer, Utah, #190547-2202
  • Professional Engineer Metallurgical, Washington, #52817
Professional Honors
  • Elected Member of the National Academy of Engineering (NAE), 2023
  • Fellow, American Society for Materials, 2003
  • Elected Member of Tau Beta Pi Engineering Honor Society
  • Elected Member of Sigma Xi Honors in Research Society
  • Recipient of the Distinguished Engineering Alumni Medal from the University of California, Davis, 2023
Professional Affiliations
  • American Society for Materials
  • Metallurgical Society of American Institute of Mining and Metallurgical Engineers
  • AWS Welding Handbook Editorial Committee; 1987
  • American Society of Mechanical Engineers—ASME

Holding degrees in both Mechanical Engineering and Materials Science and Engineering, Dr. Robert Caligiuri specializes in combining the principles of solid mechanics with an understanding of the physical, mechanical and corrosion behavior of metals to solve complex problems in industrial applications. He has over 35 years of experience conducting failure investigations, root cause studies and risk assessments for clients in the petrochemical, consumer product and transmission pipeline industries throughout North America, Europe and Asia. He has specialized expertise in the use and application of the standards, codes and regulations that govern the design, operation, and maintenance of engineered systems.

General Failure Analysis

Dr. Caligiuri has investigated hundreds of failures of metallic components in mechanical systems and structures, ranging in size from coronary implant devices to mechanical machinery to large civil engineering structures. The common thread through all of these investigations has been the relationship between the metallurgy of the component materials, and the presence of stress concentration points such as fasteners, welds, and other mechanical joints to the response of the system to applied loads. This has often required performing finite-element stress analyses of the relevant components in the system or structure. He has applied this expertise to the specific problem of failures in steel platforms, steel-frame high-rise buildings, chemical process equipment, pressure vessels, aircraft and spacecraft, construction equipment, and vehicles. He has reviewed many of the applicable codes and industry standards, including ASME, AWS, ASTM, and NACE.

Pipelines and Process Piping

Dr. Caligiuri has investigated over 75 failures in pipelines, ranging in size from 1-inch copper water distribution pipelines to downstream 16-inch liquid petroleum pipelines, to downstream 36-inch-diameter natural gas transmission pipelines. His investigations have included review and analysis of destructive and nondestructive testing, including review and interpretation of radiographic images of welds in accordance with industry standards. In addition, he has investigated the failures of components in upstream hydrocarbon production and processing facilities, including drilling strings, casings, valves, and gathering field lines. Dr. Caligiuri has researched the corrosion and stress corrosion cracking of materials exposed to H2S, and has investigated field failures of components exposed to sour environments, including welded piping. He has extensively reviewed and evaluated the applicability of most major piping-related industry standards and codes, including ASME B31.1, ASME B31.3, ASME B31.4, ASME B31.8, ASME BPVC Section IX, API-5C, API 1104, API 570, and NACE MR0175.

Welds and Welded Connections

Dr. Caligiuri has investigated numerous failures in welds and welded metallic components. The common thread through all of these investigations has been the relationship between the metallurgy of the weld metal, the heat-affected zone, and the base metal to the response of welded joints to applied loads and associated stress concentration points. Particular past experience has included welds in steel structures, pipelines, tanks and pressure vessels in refineries and chemical plants, and offshore marine facilities and terminals. He has specific experience related to the interpretation of welding procedures, specifications, codes, and standards, and their applicability to fabricated structures and mechanical systems, including AWS D1.1, AWS D1.2, AWS A5.1, ASME BPVC Section IX, and others.

Consumer Products

Dr. Caligiuri has conducted or supervised on behalf of consumer product manufacturers numerous root-cause investigations into potential safety and warranty issues. Such products have included: clothes washers, clothes dryers (gas and electric), dishwashers, refrigerators and sealed system components, ice makers, microwave ovens, conventional ovens, coffee pots, blenders and mixers, gas furnaces and water heaters, room dehumidifiers, child safety seats, disposable lighters, and automotive components such as restraint systems, airbags, transmissions, fuel delivery systems, and steering wheels. Dr. Caligiuri has pioneered the use of the top-down approach to root-cause analysis for consumer products and the use of analytical tools like FMEAs and fault trees in such studies. Selected projects are summarized below.