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Failure analysis

Definition: Failure analysis is the structured investigation of a technical component or plant failure in order to determine the primary and secondary causes of damage. It combines materials science, mechanical and operational analyses. The aim is the traceable reconstruction of the failure mechanism.

Practical relevance: The analysis covers fracture surfaces (fractography in the SEM), microstructural conditions (metallography), chemical composition (OES, EDX) as well as operating and load data. Typical mechanisms are fatigue, overload, corrosion or material mix-up. The assessment is carried out with reference to applicable standards, specifications and safety requirements.

Decision-making perspectives:

  • Technical decision-makers: Derivation of design or process improvement measures.
  • Purchasing/project management: Assessment of warranty claims or supplier responsibility.
  • Science: Investigation of crack initiation, crack growth and microstructural influences.
  • Insurance/law: Court-proof documentation of the cause of damage for the allocation of liability.

Typical testing or verification methods: SEM fractography, metallography, hardness testing, tensile test, non-destructive testing (NDT).

FAQ:

  • What is the aim of a failure analysis?
  • The unambiguous identification of the failure mechanism as a basis for prevention and liability assessment.

Failure Investigation

Definition: Failure investigation refers to the systematic examination of a technical failure case to determine the primary and secondary causes of failure. It combines materials analysis, fractography, load analysis and document review. The aim is the traceable reconstruction of the failure mechanism.

Practical relevance: The analysis covers fracture surfaces (e.g. by means of SEM), microstructural conditions, material composition (EDX/OES), mechanical properties and operating conditions. Typical mechanisms are fatigue fracture, stress corrosion cracking, overload or material mix-up (PMI). A structured approach in accordance with recognised standards increases the reliability of evidence and reproducibility.

Decision-making perspectives:

  • Technical decision-makers: Derivation of technical corrective measures and prevention strategies.
  • Purchasing/project management: Assessment of supplier responsibility and quality deviations.
  • Science: Analysis of crack initiation, crack growth and microstructural influencing factors.
  • Insurance/law: Court-proof documentation of the cause of failure and allocation of liability.

Typical testing or verification methods: Fractography in the SEM, metallography, hardness testing, tensile test, chemical analysis (EDX, OES), NDT.

FAQ:

  • What is the aim of a failure investigation?
  • The clear and traceable determination of the technical cause of failure as a basis for prevention or liability assessment.
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