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The document outlines the general procedure for failure analysis, which includes collecting background information, preliminary examination of failed components, selecting and cleaning samples, non-destructive testing, evaluating mechanical properties, macroscopic and microscopic fracture examination, metallography, establishing the fracture mechanism, simulated testing, analyzing findings, and reporting with recommendations to prevent future failures. The procedure may vary by case and investigators should avoid jumping to conclusions without proper consideration of materials, manufacturing, service history, and conditions.

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88 views8 pages

L18 PDF

The document outlines the general procedure for failure analysis, which includes collecting background information, preliminary examination of failed components, selecting and cleaning samples, non-destructive testing, evaluating mechanical properties, macroscopic and microscopic fracture examination, metallography, establishing the fracture mechanism, simulated testing, analyzing findings, and reporting with recommendations to prevent future failures. The procedure may vary by case and investigators should avoid jumping to conclusions without proper consideration of materials, manufacturing, service history, and conditions.

Uploaded by

rashmi sahoo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Failure Analysis and Prevention

General Procedure of Failure Analysis: STEPS


DHEERENDRA KUMAR DWIVEDI
MECHANICAL & INDUSTRIAL ENGINEERING DEPARTMENT

1
General procedure for failure analysis
• In the field of engineering, mechanical components are:
– made using variety of materials
– processed by different manufacturing processes and
– used in extremely wide range of the service conditions.
• Potential causes of failure of the components and their
mechanism also numerous.
Establishing FA procedure
• Therefore, procedure of the failure analysis of each
component should be different
• FA procedure for each case must be developed after giving
proper thought on
– possible sequence of events before failure
– proper evaluation of the situation
– proper consideration of
• material, manufacturing process, service history and
actual working condition etc.
Avoid hurriedness
• Failure analyst tends to jump into conclusions based on half
information and tries to prepare the samples for metallographic
studies to look explore the deficiency in the material itself.

• This kind of quickness is uncalled for and in this process vital


clues, evidences and information can be lost from the surface of
the fractured components.
So how to go ahead
• Steps for FA are generic and need not to be followed in the
specified sequence.
• The sequence of steps for FA will largely be determined by the
findings of the investigation at any stage.
• Main objective of collecting evidences regarding causes of the
failure is to establish sequence of events prior to the failure
• Provide suitable recommendations to prevent the similar
failure in future.
General procedure for FA
• Collection of back ground information about failed components:
Mfg, design, service
• Preliminary examination of failed components: parts, conditions,
locations, photography, inventory
• Selection, preservation and cleaning of the sample
• Assessing the presence of discontinuity and defect in failed
component by non-destructive testing
General procedure for FA
• Evaluation of the mechanical properties of the failed
components
• Macroscopic observation of fracture surfaces and
components
• Microscopic examination of fracture surfaces and components
• Metallographic examination of failed components including
chemical analysis
• Establishing the fracture mechanism
General procedure for FA
• Failure analysis using fracture mechanics
approach
• Conducting test under simulated conditions
• Analysis of findings of investigation
• Report writing with recommendation

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