Metallurgical Failure Analysis

The study of failures of metallic materials and components is the subject of the specialist area of failure analysis known as “metallurgical failure analysis,” which seeks to understand and pinpoint the causes of such failures. It is a crucial step in many industries, particularly those that employ metallic materials frequently, such as aerospace, automotive, manufacturing, petrochemical, and others. Understanding the underlying reasons for failure, avoiding a repeat of it, and improving the dependability and safety of metal parts and structures are the objectives of metallurgical failure analysis.

Title: Metallurgical Failure Analysis

Metallurgical Failure Analysis is the systematic examination, testing, and analysis of a failed metal component or material to understand its failure and prevent future ones. It involves preliminary investigation, visual examination, non-destructive testing (NDT), fracture analysis, metallographic examination, mechanical testing, chemical analysis, and root cause analysis. The process involves collecting and reviewing information about the component, its service history, and conditions leading up to the failure, such as manufacturing, the operational environment, and unusual incidents or maintenance operations. Visual examination can identify corrosion, cracks, deformations, and other signs of failure, while NDT methods can reveal flaws or discontinuities in the material. Fractographic analysis examines fracture surfaces, while metallographic examination examines the structure of the metal or alloy, determining its properties and mechanical behavior.

Mechanical testing, chemical analysis, and root cause analysis are used to determine the root cause of the failure, which may involve a manufacturing defect, design flaw, inappropriate material selection, misuse, or a combination of these factors. The results of the failure analysis are compiled into a detailed report, providing a summary of the findings, evidence supporting them, and recommendations for preventing similar failures in the future. The experts will identify the primary factor that led to the failure and help develop prevention strategies, whether it be fractures, formability issues, corrosion, or wear.

Read more: Using Electron Microscopy in Metallurgical Failure Analysis Lab Services

A wide range of materials, including alloy steels, stainless steels, titanium alloys, superalloys, copper and aluminum alloys, plastics, ceramics, and glass, are routinely the subject of failure assessments by metallurgists and professional engineers.

To identify the source of a problem, failure analysts frequently employ a variety of test methods. The most popular ones include visual inspection, optical fractography, scanning electron microscopy, energy dispersive spectroscopy, hardness testing, mechanical testing, x-ray diffraction, chemical analysis, and metallographic methods.

The Failure Analysis Group can consult engineers in other divisions, such as Forensics, Mechanical Engineering, and Dimensional Inspection, should the scope of the investigation require additional knowledge.

Video 01: What To Expect From a Metallurgical Failure Analysis