A Step-by-Step Guide to Conducting Failure Analysis

18 Apr A Step-by-Step Guide to Conducting Failure Analysis

The systematic process of failure analysis in metallurgy entails determining the underlying reasons of material failures in order to stop them from happening again and enhance product performance. This comprehensive manual describes the essential steps and methods for carrying out failure analysis in metallurgy.

1.Define the Scope and Objectives 

• Clearly state what the failure analysis will cover, including the component that failed, how it worked, and the intended result.

•   Set goals like figuring out the main reason behind the failure, recognizing the contributing elements, and suggesting solutions.

2. Acquire Background Information

•  Compile pertinent details on the malfunctioning component, such as its material composition, manufacture background, operating circumstances, and maintenance surroundings.
•  Examine all of the material that is at your disposal, including engineering drawings, specifications, maintenance logs, and accounts of prior failures.

3. Visual Inspection

•   Examine the failed component closely to look for any obvious evidence of wear, corrosion, deformation, damage, or fracture.
•  Take notes, make sketches, or take pictures of observations to record significant details.

4. Non-Destructive Testing (NDT)

• Depending on the size, suspected failure mode, and material of the component, choose the proper NDT procedures. 

5. Sample Preparation

•  Based on the observed damage and suspected failure mechanisms, choose suitable   places for sampling.
•  Use the correct cutting, machining, or sectioning processes to carefully remove representative samples from the malfunctioning component.
•   Treat samples carefully to prevent further deterioration or microstructure modification.

6.Microscopic Examination

• For a microscopic examination, you must mount, grind, polish, and etch metallographic samples before using a microscope to see their substructure.
• Look at the substructure with optical transmission, or scanning electron microscopy (SEM) to find flaws, inclusions, phase distribution, and grain structure.

7. Mechanical Testing 

• This is how you find out how hard, ductile, tough, and tension strong a material is.
• Test standard samples that haven’t been affected and samples that have failed so that you can compare and analyze them.

8. Failure Mechanism Identification

• Look at the information gathered from eye inspection, nondestructive testing (NDT), microscopy, chemical analysis, and mechanical testing to find the main cause or causes of failure.
•  Think about things like deteriorating materials, mistakes in manufacturing, corrosion, wear, overuse, and tiredness.

9. Root Cause Analysis 

• When looking for possible root causes of failure, you should think about the failure mechanism(s) and factors that led to the failure.
•  Take into account production procedures, operational circumstances, maintenance procedures, material selection concerns, design defects, and outside influences.

In order to comprehensively study material failures, conducting failure analysis in metallurgy necessitates a systematic approach that integrates a variety of methodologies and approaches. MTS Metallurgists efficiently determine the core reasons of failure, put remedial measures in place, and improve the performance and reliability of their products by following this step-by-step guidance.