Introduction
Failure analysis refers to the systematic process used to understand the actual reason behind a component or system failing. Having insight into the actual mechanisms can aid engineers, scientist in avoiding similar events moving forward, and designing better products with less risk. This article explains the basics of failure analysis, what methods are used for finding them and how it is useful in different sectors.
Failure Analysis: Why it Matters
Enhance products: Identifying failure modes allows engineers to design better, more robust and reliable products.
Lowering Costs: By avoiding failures, we save both preventative maintenance costs and replacement costs.
SAFETY IMPROVEMENT : Knowledge of failure mechanisms aids in reducing the risk and hence, safety of users.
Forensic Analysis: Failure analysis can play a key role in investigations related to disputes and regulatory authorities.
The Failure Analysis Process
Problem Definition:
Specify what the failure mode is, and how we will know about it.
Consult available data, including normal and abnormal operation history, maintenance records, and environmental records.
Visual Inspection:
Please conduct a detailed visual inspection of the failed part.
Examine for any macroscopic flaws such as cracks, corrosion or deformation.
Nondestructive Testing – NDT
Utilize non-destructive testing methods (NDT) like X-ray radiography, ultrasonic inspection or eddy current inspection to check internal flaws without harming the part.
Destructive Testing:
If you need to, take apart the component to see what makes it tick.
Metallographic, fractographic and/or chemical analyses may also be used to examine the material properties and failure mechanisms.
Root Cause Analysis (RCA):
Determine the root-cause of the demise.
Material defects, manufacturing errors, design flaws or calls to use the product in a way that could cause injury.
Corrective Action:
Put in place corrective measures to avoid failure at some point.
This could involve design changes, process improvements or substitute materials.
Some of these failure analysis techniques are fairly common.
Metallography: Involves the analysis of the microstructure of metals and thereby detecting various types of defects as well as its material properties
Fractography: Studying fracture surfaces to identify the fracture mode (brittle fracture versus ductile fracture)
