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Failure Analysis Introduction

Failure analysis is a systematic process for investigating the root causes of failures in components or systems, aimed at preventing recurrence. It involves categorizing failures, collecting data, conducting inspections and tests, and determining corrective actions. Essential for safety, reliability, and cost savings, failure analysis also supports continuous improvement in design and manufacturing.

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6 views4 pages

Failure Analysis Introduction

Failure analysis is a systematic process for investigating the root causes of failures in components or systems, aimed at preventing recurrence. It involves categorizing failures, collecting data, conducting inspections and tests, and determining corrective actions. Essential for safety, reliability, and cost savings, failure analysis also supports continuous improvement in design and manufacturing.

Uploaded by

ranganathanb893
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© © 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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Introduction and Need for Failure Analysis - Full Detailed Explanation

1. Introduction to Failure Analysis

Failure analysis is a systematic, scientific process used to investigate the cause of a failure in a

component, material, structure, or system. This failure could be sudden or progressive and may

involve physical breakdown, malfunction, or degradation over time.

Definition:

Failure Analysis is the process of collecting and analyzing data to determine the root cause of a

failure, with the objective of preventing it from happening again.

Failures are not merely breakdowns; they are learning opportunities that reveal critical flaws in

design, manufacturing, materials, or operation.

2. Types of Failures

Understanding the categories of failure is the first step in analysis:

Mechanical - Fracture, fatigue, overload (e.g., broken gear tooth)

Thermal - Deformation or cracking due to heat (e.g., turbine blade failure)

Chemical - Corrosion, oxidation (e.g., rusted pipeline)

Electrical - Short circuits, insulation breakdown (e.g., transformer failure)

Human/Operational - Misuse, poor maintenance (e.g., crane collapse due to overload)

3. Failure Analysis Process - Step-by-Step


Step 1: Collection of Background Data

- Component details (design, material, manufacturing method)

- Operating conditions (load, temperature, environment)

- Failure history (when, how, and what happened)

Step 2: Visual Inspection

- Surface examination

- Check for deformation, cracks, discoloration, wear, or corrosion

Step 3: Non-Destructive Testing (NDT)

- Methods like Ultrasonic Testing (UT), Radiography, Magnetic Particle Testing, Dye Penetrant

- Helps to detect internal flaws without damaging the part

Step 4: Material Analysis

- Metallography: Study of grain structure under microscope

- Chemical analysis: Check composition using spectrometers

- Hardness, tensile, and impact tests

Step 5: Fractography

- Examination of fracture surfaces under a Scanning Electron Microscope (SEM)

Step 6: Root Cause Determination

- Tools: Fishbone diagrams, Failure Mode and Effects Analysis (FMEA), 5 Whys

Step 7: Corrective Actions and Recommendations

- Design/process improvements, better maintenance


4. Need for Failure Analysis - Why It Is Essential

a) Safety Assurance - Prevent catastrophic failures (e.g., aviation, nuclear)

b) Reliability Improvement - Increases component life and trust

c) Cost Savings - Reduces repair, downtime, legal, and recall costs

d) Legal & Insurance Evidence - Determines liability and provides proof

e) Process & Design Optimization - Continuous improvement in design and production

f) Quality Control - Detect and prevent defects during manufacturing

g) Customer Satisfaction - Builds brand reputation

5. Real-World Examples of Failure Analysis

Case 1: Tacoma Narrows Bridge Collapse (1940)

- Cause: Aeroelastic flutter due to wind resonance

Case 2: Aloha Airlines Flight 243 (1988)

- Cause: Fatigue cracks in fuselage skin

Case 3: Space Shuttle Challenger (1986)

- Cause: O-ring failure at low temperatures


6. Conclusion

Failure analysis is not about assigning blame, but about learning and improving.

It ensures safety, reliability, and cost-efficiency in engineering systems.

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