Strategies and Techniques to Optimize Process

Gaining Deep Insights on the Process of Failure Analysis

Failure analysis is an essential process for determining why a metal product has failed to perform or deteriorated to the point of being unsafe to use. A metallurgical root cause failure analysis is conducted by experienced engineers in a lab setting utilizing advanced metals science expertise. Through the lab’s testing and inspection services, the structural and behavioral results required for a thorough investigation can be obtained. The lab’s Scanning Electron Microscope with EDS capabilities is used to detect flaws or inconsistencies that may indicate the root cause of the failure.

By providing as much relevant information as possible, including the composition and fabrication of the failed item, the circumstances leading to the material failure, and the failure event details, the engineers can conduct a root cause failure analysis based on the type of product and its history. This involves utilizing the necessary testing and inspection services to identify the cause of failure. Mechanical testing, metallurgical evaluation, chemical analysis, nondestructive testing, and dimensional inspection services are all used in the failure analysis process.

A comprehensive Failure Analysis Report is provided to customers once the metal failure analysis is completed. This Report may include suggested actions to be taken with similar parts or materials in the future to avoid a recurrence. It also includes information on the cause and prevention of failure.

Failure Analysis Procedure

Here is a general failure analysis procedure:

Clarify the Scope: Specify the goals and parameters of the failure analysis. Recognise the failure’s context, which includes the operational circumstances, service history, and any available history.

Collect Information: Compile pertinent data regarding the failed system or component, including design characteristics, operating conditions, maintenance logs, and any other documentation or data that may be accessible.

Visual Inspection: Check the component or system that has failed visually for any indications of damage, deformation, fractures, or other irregularities. For documentation, pictures or sketches may be taken.

Use non-destructive testing (NDT) methods to further evaluate the component without causing more harm, such as visual examination, ultrasonic testing, radiographic testing, or magnetic particle testing.

Sample Gathering: If necessary, gather samples from the malfunctioning component for additional laboratory testing. To ensure representative sampling and maintain the samples’ integrity, care should be taken.

Various laboratory tests and analyses, including metallurgical analysis, chemical analysis, mechanical testing, microscopy, spectroscopy, or thermal analysis, should be carried out on the samples that were gathered. These tests assist in identifying material characteristics, flaws, corrosion, fatigue, or additional failure-causing causes.

Analyze the data to determine how the results of the visual inspection and laboratory testing relate to the failure that was actually witnessed. Determine any departures from desired conduct or requirements.

Determine the failure’s root cause or causes based on the information that has been gathered and examined. This could entail taking into account elements like design flaws, material weaknesses, production problems, environmental conditions, or operational elements.

Prepare a thorough failure analysis report that details the results, identifies the fundamental cause, and makes suggestions for changes or corrective measures to avoid such failures in the future.

Implement Corrective Actions: Adopt the necessary corrective actions in accordance with the recommendations in order to address the underlying issue and stop similar failures from happening in the future.

Video 01: Ansys Reliability Engineering Services: Failure Analysis

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