Materials Failure Analysis

 

Failure analysis is the process of collecting and analyzing data to determine the cause of a failure, often with the goal of determining corrective actions or liability. It is an important discipline in many branches of manufacturing industry, such as the electronics industry, where it is a vital tool used in the development of new products and for the improvement of existing products. The failure analysis process relies on collecting failed components for subsequent examination of the cause or causes of failure using a wide array of methods, especially microscopy and spectroscopy. The NDT and non-destructive testing methods are valuable because the failed products are unaffected by analysis, so inspection sometimes starts using these methods.

We undertake failure analysis with networks of PE’s and NACE Certified Corrosion/Materials Selection/Design qualified metallurgists, chemical engineers, technologists and scientists who are some of the most experienced in their field. Using an extensive range of proven techniques and applications, we provide analysis of and insight for solving your asset failures, from pipeline failure assessment to commercial building corrosion risk analysis; evidence analysis to material characterization; and finally forensic engineering and litigation support      

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We undertake failure analysis with networks of qualified metallurgists, chemical engineers, technologists and scientists who are some of the most experienced in their field. Using an extensive range of proven techniques and applications, we provide analysis of and insight for solving your asset failures, from pipeline failure assessment to commercial building corrosion risk analysis; evidence analysis to material characterization; and finally forensic engineering and litigation support.

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Stress Corrosion Cracking

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Galvanic Corrosion

asset failure can have far reaching consequences, which impact reputation, scheduling, and the bottom line. Our consulting services will improve your understanding of the causes of asset failure and provide practical cost-effective options for remedial action. Our consultants work with you to prevent future failures. We are allied with customers in the oil and gas industry, electric generation/transmission , water and materials related industries and we service a comprehensive range of industries, including commercial building industries.

Engineering and Consulting Services

– Metallurgical Engineering
– Inspection and Risk Assessment
– Failure Analysis and Prevention
– Product Design and Development
– Feasibility Studies

 

– Vendor Selection
– Design with Materials for Manufacturing
– Materials Testing and Code Compliance
– Advanced Manufacturing Technologies
– Materials Selection and Design Analysis

We undertake failure analysis with networks of qualified metallurgists, chemical engineers, technologists and scientists who are some of the most experienced in their field. Using an extensive range of proven techniques and applications, we provide analysis of and insight for solving your asset failures, from pipeline failure assessment to commercial building corrosion risk analysis; evidence analysis to material characterization; and finally forensic engineering and litigation support.

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Through multidisciplinary, systematic analysis, inspection and testing we attack the failure holistically, examining related systems, material characteristics, individual parts, maintenance, environment, product specs, history, design, existing conditions, or a combination of such factors. We determine how and why the failure occurred, focusing on the mode and the root cause, whether it be the material itself, e.g., fatigue, embrittlement, or environmental interactions or degradation, e.g., corrosion or contaminants, creep in elevated temperatures, manufacturing defects, design deficiencies, improper handling or product selection, galvanized pipe in contact with soft corrosive water.

We provide solutions that work, delivering clear and specific solutions and improved operations. We recommend economical and practical proposals that are compatible with your existing systems and processes and allow you to learn from the past experiences and improve your future.

Failure  Analysis Root Cause Investigation-Our Approach

Once it has been determined that a failure has indeed occurred, the point of origin must be found, and a determination must be made as to whether the failure occurred as a result of design, method of manufacturing, service history and conditions, soil/water chemistry excursions, or from a deficiency in the material. When the point of origin is located, the investigation may proceed to a study of how the failure occurred, possible causes or factors in the failure, and possible means of preventative measures.

Why a failure occurs is an important question in the method of evaluation. This question can be approached by breaking down the failure into “mode of failure” and “cause of failure.” Mode of failure is the process by which the failure occurred. Cause of failure is that which can be fixed or changed to prevent future failures. Each question provides important clues to the investigation, and although priorities may be quite different, each question must be addressed and resolved to determine why a failure may have occurred.

Several important factors often associated with component failures are  over loading conditions, vibrations, corrosive environments, deficiency in design, fabrication, operating conditions, unsuitable materials selection, and expended useful life. Our failure analysis procedure, or methodology for evaluation, will be  provided in a step by step approach. This includes justification for conducting a failure analysis investigation, developing a logical plan for the investigation to follow, collection of background information, sample removal techniques, on-site inspection, laboratory testing and analysis, and the formulation of a final report based on relevant data, analysis, and recommendations.

Your input is vital for our failure analysis root cause determination. By giving us a detailed description of the failure, you can be sure that all aspects of failure investigation will be considered promptly. We’ll send you a proposal for your work/project, including methods, testing, specific recommendation  and costs.