What is Failure Analysis and its Significance?

Failure Analysis

Failure analysis is a methodical assessment of a system, process, or product’s flaw. It is a multidisciplinary strategy used to pinpoint the root causes of failure and recommend remedies to stop it from happening again. Industry sectors like manufacturing, aviation, electronics, civil engineering, and many more depend heavily on failure analysis. Increasing the performance or reliability of a product is a common goal of failure analysis.

Whether your business is an OEM or a seller, your reputation is on the line when a part fails. To fix the problem and ensure your clients’ trust in you, a failure analysis must respond to three crucial questions. These are the inquiries:

How did it go wrong?

How did it fail?

What will ensure its success?

Nothing has been resolved if your investment in a failure analysis cannot address ALL THREE of these issues.

Around 12,000 Failure Analyses have been carried out by Metallurgical Associates. We are seasoned failure analysis professionals, and each failure analysis service we provide includes a clear, detailed response to the three crucial questions.

The Three Fundamental Issues

How did it go wrong?

A multitude of mechanisms, or modes, by which materials fail show distinctive microscopic characteristics. Corrosion, wear, hydrogen embrittlement, stress corrosion cracking, creep, and environmental deterioration are examples of typical failure modes. Using the most recent developments in stereo optical microscopy, high magnification SEM analysis, and microstructure analysis, MAI engineers pinpoint the failure mode.

How did it fail

Material properties, manufacturing processing history, design, service conditions, or a combination of these factors cause variations in failure mode. One or more of these parameters also match the primary cause of failure. Where necessary, we conduct mechanical testing, chemical analysis, and other tests to ascertain the properties of the material. Analysis of the hardness, micro-hardness, and microstructure reveals the history of the manufacturing process. EDS analysis is used to locate pollutants, wear particles, or environments that are corrosive. To find design flaws or service abuse, service stress is calculated and compared to material attributes. Engineers from MAI assess and examine test results and service records to pinpoint the precise reason for failure.

What will ensure its success?

It is simple to identify recommendations that prevent failures. Another issue is making recommendations that are affordable, doable, and compatible with your current manufacturing procedures. The solutions offered by MAI Materials Engineers are the result of their experience and knowledge. To ensure that suggested modifications are implemented successfully, we work together with our clients.

Outcomes – After we finish our study, we promptly send the fully documented report with our suggestions. A physical copy can also be provided by UPS or FedEx upon request. Our reports concisely and simply convey our conclusions and suggested solutions. Through phone or email, MAI engineers are always accessible to respond to inquiries and go over reports.

Studying failure analysis in cases

A wide number of industries can benefit from the failure analysis offered by Metallurgical Associates. Our assessments pinpoint the root cause and kind of failure, but more importantly, we offer workable, affordable alternatives to the production process or design to avert further failures.

Video 01: Failure Analysis and Prevention