Why Failure Analysis & Material Investigation is Critical

Unexpected failures in industrial components, structures, or machinery can lead to downtime, safety hazards, and financial losses. However, every failure carries with it clues — visual, structural, and chemical — that tell the story of what went wrong.

Failure Analysis & Material Investigation is the systematic process of gathering and analyzing data to determine the cause of a failure. At MTS India, we use this process to help our clients:

• Prevent future failures through corrective action
  
  
• Improve design, manufacturing, and maintenance practices
  
  
• Ensure safety and compliance in critical systems
  
  
• Resolve disputes in insurance or legal claims
  
  
• Support R&D with real-world insights
  
  

Our Failure Analysis Approach

What sets MTS India apart is our comprehensive and methodical approach to Failure Analysis & Material Investigation. Our process includes:

1. Initial Consultation & Evidence Collection

We begin by understanding the problem and collecting as much background data as possible. This includes operational conditions, service life, environmental exposure, material specifications, and previous repair or inspection records.

Physical evidence such as failed components, debris, or photographs is also gathered. Preserving the original condition of the failed item is vital, so we encourage clients to avoid cleaning or tampering with samples before submitting them.

2. Non-Destructive Testing (NDT)

Before cutting or altering the sample, our engineers employ non-destructive testing techniques such as:

• Ultrasonic testing (UT)
  
  
• Magnetic particle inspection (MPI)
  
  
• Dye penetrant testing (DPT)
  
  
• Radiographic examination (X-Ray)
  
  

These techniques help detect surface and subsurface flaws without compromising the integrity of the evidence.

3. Visual and Macroscopic Examination

A careful visual and macroscopic inspection provides the first set of clues. Signs of overheating, corrosion, abrasion, misalignment, fatigue cracks, or mechanical overload often become evident during this stage.

Our high-resolution digital imaging and stereo microscopy help document critical fracture features and deformation patterns.

4. Microscopic & Metallurgical Examination

Using powerful optical and scanning electron microscopes (SEM), our metallurgists examine grain structure, fracture surfaces, inclusion content, heat treatment effects, and micro-crack propagation.

Metallographic cross-sections are prepared to assess:

• Phase distribution
  
  
• Weld integrity
  
  
• Case depth
  
  
• Grain boundary failures
  
  
• Intergranular corrosion
  
  

5. Chemical & Mechanical Testing

Understanding material composition is essential. Our lab performs advanced chemical analysis using:

• Optical Emission Spectroscopy (OES)
  
  
• X-Ray Fluorescence (XRF)
  
  
• Energy-Dispersive X-ray Spectroscopy (EDS)
  
  

Mechanical testing is also done to compare current properties with design specifications. This includes:

• Tensile testing
  
  
• Hardness testing
  
  
• Impact testing
  
  
• Fatigue testing
  
  

6. Root Cause Analysis & Reporting

The evidence gathered is then pieced together by our multidisciplinary team of material scientists and engineers. We apply root cause analysis tools such as:

• Fishbone diagrams
  
  
• 5 Whys method
  
  
• Fault tree analysis (FTA)
  
  
• Failure Mode and Effects Analysis (FMEA)
  
  

A comprehensive report is provided, detailing the findings, probable causes, contributing factors, and actionable recommendations to prevent recurrence. High-quality visuals, test results, and conclusions are compiled for your technical and management teams.

Industries We Serve

Our Failure Analysis & Material Investigation services are trusted across a wide spectrum of industries, including:

• Automotive – crankshaft failures, brake disc cracking, engine wear
  
  
• Oil & Gas – pipeline leaks, valve corrosion, weld integrity
  
  
• Aerospace – fatigue failure in aircraft parts, coating delamination
  
  
• Power & Energy – turbine blade fractures, insulation breakdowns
  
  
• Construction & Infrastructure – rebar corrosion, structural joint cracking
  
  
• Manufacturing & Tooling – die failure, mold cracking, bearing wear
  
  

From single part evaluations to large-scale failure investigations, MTS India delivers precision and reliability at every step.

Why Choose MTS India for Failure Analysis & Material Investigation?

When you work with MTS India, you gain access to:

 ✅ ISO-compliant laboratories with advanced analytical equipment
✅ Highly experienced metallurgists and forensic engineers
✅ Unbiased, third-party analysis with legal documentation support
✅ End-to-end testing under one roof – chemical, mechanical, NDT, microstructural
✅ Fast turnaround time without compromising on accuracy

We combine decades of industry experience with scientific rigor to help you solve your toughest engineering problems.

Frequently Asked Questions

Q1. How long does a typical failure analysis take?

A: Depending on complexity and number of tests involved, a typical analysis takes 5–15 business days.

Q2. Can you analyze failures on-site?

A: Yes, MTS India offers on-site visual inspections, sample collection, and portable NDT services for large or immovable equipment.

Q3. Do you provide support for legal or insurance claims?

A: Absolutely. Our investigation reports are defensible in court and often used in litigation, arbitration, and insurance assessments.

Q4. What is the cost of a failure investigation?

A: Pricing varies based on the nature of the failure, tests required, and reporting scope. Contact us for a custom quote.

Contact MTS India Today

When failure strikes, don’t just replace the component — understand why it failed. Let MTS India’s Failure Analysis & Material Investigation experts uncover the truth behind material behavior and operational breakdowns.

📞 Call us at +91 98417 07777

 📧 Email: info@mts-india.in

 🌐 Website: https://mts-india.in/

Explore our state-of-the-art lab, talk to our engineers, and start your journey towards better performance, safety, and reliability.