Corrosion Failure Analysis

Corrosion is the degradation of a material caused by a reaction with its surrounding environment. When corrosion causes material failure, it is essential to conduct a root cause analysis to identify the mechanism and implement corrective measures. Corrosion failure analysis is used not only to determine the cause of failure but also to prevent future failures.

Failure analysis specialists can be involved at any point in a product’s life cycle, from design and production through operation to failure analysis. The purpose of their involvement is to analyse material degradation and suggest ways to prevent corrosion.

The Eight Common Types of Corrosion

Structures and engineered products most commonly experience:

1. Uniform corrosion attack
2. Galvanic corrosion
3. Crevice corrosion
4. Pitting corrosion
5. Intergranular corrosion
6. Selective leaching
7. Erosion corrosion
8. Stress corrosion cracking

Each mechanism has distinct characteristics, causes, and preventive strategies. Correct identification is crucial for effective remediation.

Key Steps in Corrosion Failure Analysis

A complete investigation of corrosion failure will typically involve the following step-by-step procedure:

1. Information Gathering
   We begin by gathering all relevant site information: operating conditions, environmental exposure, service history, maintenance information, and material properties. This enables us to better identify possible corrosion causes and contributing factors.
2. Visual and Microscopic Examination
   A thorough first-pass analysis involves extensive visual examination and microscopic analysis to assess surface damage, corrosion, crack origins, and fracture characteristics, providing initial indications of the mechanisms of failure.
3. Non-Destructive Testing (NDT)
   Ultrasonic testing, radiography, and dye penetrant testing are used to inspect the component internally for cracks, voids, or subsurface damage without damaging it.
4. Material Characterization
   We also analyse the mechanical, chemical, and thermal properties to confirm compliance with specifications and to determine whether material defects may have caused the failure.
5. Sample Selection
   Representative samples are carefully selected from critical regions to ensure that the laboratory analysis results accurately represent the failure condition and are not misleading.
6. Macroscopic Fracture Analysis
   The fracture surfaces are inspected to determine the patterns of cracking, whether it was a brittle or ductile failure, the presence of corrosion deposits, and other details that can be used to piece together what happened.
7. Advanced Analytical Techniques
   Methods such as SEM, EDX, and XRF are employed to investigate microstructural details and chemical composition, providing a detailed understanding of corrosion products and elemental distribution.
8. Metallurgical Examination
   Prepared microsections are enlarged to examine the structure of grains and phases, the quality of welds, inclusions, and intergranular attack, all of which contribute to material degradation.
9. Identification of Failure Mechanism
   All the evidence is synthesized to identify the dominant corrosion process, recognizing that multiple corrosion processes may have contributed to the observed damage.
10. Data Review and Conclusion
    The collected data, laboratory results, and analyses are systematically reviewed to identify the root cause and validate the sequence of events leading to failure.
11. Recommendations and Reporting
    A detailed report summarizes results, conclusions, and recommendations to avoid recurrence, make better material selections, and improve system reliability.

Importance of Corrosion Failure Analysis

Analysis of corrosion failures may be time-consuming and expensive, and may involve cooperation between metallurgists, materials scientists, corrosion engineers, and attorneys. Nevertheless, a professional analysis is worth the cost. It can:

• Prevent recurrence of failures
• Improve product design and material selection
• Support insurance or product liability claims
• Serve as expert evidence in legal proceedings

Conclusion

Corrosion failure analysis is a critical process for understanding material degradation and preventing future damage. Through systematic investigation, advanced analytical techniques, and expert interpretation, organizations can enhance product reliability, improve safety, and reduce long-term operational risks. Proper analysis not only resolves current failures but also strengthens future engineering decisions.

Why Choose Infinita Lab for Corrosion Testing?

At the core of this breadth is our network of 2,000+ accredited labs in the USA, offering access to over 10,000 test types. From advanced metrology (SEM, TEM, RBS, XPS) to mechanical, dielectric, environmental, and standardized ASTM/ISO testing, we give clients unmatched flexibility, specialization, and scale. You’re not limited by geography, facility, or methodology—Infinita connects you to the right testing, every time.

Looking for a trusted partner to achieve your research goals? Schedule a meeting with us, send us a request, or call us at (888) 878-3090  to learn more about our services and how we can support you. Request a Quote