Engineering Failure Analysis

Amena Jalil Junior Engineer National Centre for NDT (NCNDT)

Engineering Products and Their Performance

Main stages in the history of an engineering product

Engineering Products and Their Performance Contd

Engineering design is essentially a decision making process . (i) geometry and dimensions of different parts, (ii) types of materials used in manufacturing and their specications, (iii) fabrication and assembling techniques, and (iv) service conditions. Design is initiated after establishing the market need for a new product or improving the performance of an existing product.

Engineering Products and Their Performance Contd

Following this stage, the design is materialized into a commercial product by the manufacturer.
Finally, the product is put into service to meet its functional requirements specifying the procedures of start-up and shut down as well as the maintenance procedure and its schedule.

Failure of Engineering Products

When an engineering product ceases to perform one or more of its functions well before its expected service life, it is said to fail. Failures can cause loss of lives, unscheduled shut downs of plants, increasing maintenance and repair costs as well as very costly litigation and damages . Weakest link in the chain.

Denition and Objective of Failure Analysis Investigations

To determine the cause of failure of a certain product. Findings are documented in a report. Results of failure analysis investigations can be extremely useful to designer s of the same or similar products.

Denition and Objective of Failure Analysis Investigations Contd Manufacturers can also use the results of failure analysis investigations for marketing purposes to promote a new product with better performance capabilities.
Furthermore, by identifying the deciencies of certain structural materials through failure analysis investigations, it is possible to develop new materials or improve the properties of existing materials.

Typical Defects
Material imperfections, defects generated during service, and defects introduced as a result of faulty design practice. Defects can be found within the original material supply or can be introduced during the manufacturing process.

Failure Analysis Procedure

Dependent upon the particular case. 1. What is the mode of failure? 2. What is the most probable cause of failure? 3. How can failure be prevented in the future?

Failure Analysis Procedure Contd

Any effective failure analysis investigation must involve three main stages: (i) clear definition of the problem (ii) complete search of the literature (iii) development of an experimental program

Definition Of The Problem

Analyst meets with concerned personnel such as process engineers, maintenance engineers, etc. to discuss the problem. Ask questions.. Inspection of failure site. Photographic documentation of the failed component. Depth of information obtained, site inspection, as well as the skill and judgment of the analyst.

Failure analysis of PSV springs of 17-4PH stainless steel

Methodology
Chemical analysis Examination of the fractures. Microstructural examination Hardness measurements. Observation of the cracking surfaces in the scanning electron microscope .