Weld Failure Analysis

Weld failure analysis is a procedure used to ascertain the cause of a failed weld and how to avoid repeat failures. In many different industries, including construction, automotive, shipbuilding, and oil and gas, weld failures can have major repercussions, including safety hazards and financial losses. 

The preliminary investigation involves gathering information about the weld, including the welding process, materials, welder qualifications, welding parameters, and service conditions. Visual examination is essential for identifying signs of failure, while non-destructive testing (NDT) techniques like radiographic testing, ultrasonic testing, magnetic particle inspection, and dye penetrant inspection can reveal internal defects or discontinuities. Microscopic examination of fracture surfaces can reveal fracture type, origin, and propagation. A macroscopic examination of the weld cross-section can provide information about geometry, penetration, and potential defects. Mechanical testing, such as tensile, bend, impact, or hardness testing, is necessary depending on the suspected failure mode.

Chemical analysis can confirm the base metal and weld metal compositions, identifying material-related factors. Failure mode and root cause analysis can be conducted using collected data to determine the failure mode and root cause, which could be related to design, material, welding process, or service conditions. Report writing summarizes the analysis process, explains the cause of failure, and provides recommendations to prevent future failures.

Infinita Lab has been conducting quality tests and inspections. Daily field weld evaluations are carried out, and our technically sophisticated labs undertake weld failure analyses.

Our experts and engineers have the knowledge and tools necessary to precisely identify any fault or discontinuity, whether we are checking bridge welds or looking through weld coupons for certification purposes. Currently, we provide services to a wide range of sectors, including automotive, aerospace, construction, maintenance, manufacturing, nuclear, petrochemical, power generation, pulp and paper, pipelines, railways, amusement parks, storage tanks, and maritime. We conduct testing and inspections in accordance with industry standards and laws.

Our weld failure analysis team uses a variety of testing methodologies to identify the underlying causes of failures.

The following tests are carried out :

• Visual Examinations
• Metallography using Scanning Electron Microscopy (SEM)
• NDT Examinations (liquid penetrant, magnetic particle, ultrasonic, traditional radiography, and computed digital radiography)
• A load test
• Tensile testing with macro-etching
• Macro/Microhardness
• PMI/Chemical Analysis
• Impact Drop Weight Impact Bend Testing using Charpy

H3 Failure Analysis of Welds

Our Forensic Service Department provides legal support if a weld failure results in property loss or bodily injury. Failure analysis, consulting, standards research, thorough report writing, and expert witness testimony are all parts of this help.

What a Root Cause Analysis Can Show:

• Overload Welding
• Unsafe Welding Techniques
• Metalworking Insufficiencies
• Welding errors
• Problems with Joint Design
• Either wear or corrosion

Video 01: Welding Failures Explained