Failure Analysis

Metallic failure analysis is a crucial process in understanding why metal components fail to perform as expected. This analysis helps in identifying the root cause of the failure, which can be due to various factors such as material defects, manufacturing issues, or operational conditions. 

Key Steps in Metallic Failure Analysis:

• Visual Inspection: The first step involves a thorough visual examination of the failed component to identify any obvious signs of damage or wear.
• Non-Destructive Testing (NDT): Techniques like ultrasonic testing, radiography, and magnetic particle inspection are used to detect internal defects without damaging the component.
• Microscopic Examination: Using optical and electron microscopes to study the microstructure of the material and identify any microscopic defects or anomalies.
• Chemical Analysis: Determining the chemical composition of the material to check for any impurities or deviations from the specified alloy composition.
• Mechanical Testing: Assessing the mechanical properties of the material, such as hardness, tensile strength, and impact resistance, to ensure they meet the required standards.
• Fractography: Analyzing the fracture surface of the failed component to identify the mode of failure (e.g., brittle, ductile, fatigue, or corrosion).
• Root Cause Analysis: Combining all the gathered data to determine the primary cause of the failure and suggest corrective actions to prevent future occurrences.

 Common Failure Modes: 

• Brittle Fracture: Sudden failure without significant deformation, often due to low temperatures or high strain rates.
• Ductile Fracture: Failure after significant plastic deformation, usually due to overload or material fatigue.
• Fatigue: Progressive failure due to cyclic loading, leading to crack initiation and propagation.
• Corrosion: Degradation of the material due to chemical reactions with the environment, leading to pitting, stress corrosion cracking, or intergranular corrosion.