Failure Analysis in Materials Testing

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Failure analysis is a detailed process that is applied to different types of supplies. Every group of materials requires some specific skills and experience that can help one solve the causes of failure. The objective of failure analysis is simple/l to prevent future failures. The main cause of failures is when a structure or part of one does not perform in accordance with the expectations with which it was created.

The hypothesis of failure is one that is understood intuitively however, there are several underlying crucial conceptual principles which are usually misunderstood or completely ignored. There is a particular type of failure analysis that is associated with something called No Fault Found (NFF) which is a term that is used in the field to explain a situation in which an originally reported method of failure cannot be replicated by the technician who is evaluating it and so, the potential defect cannot be fixed.

Failure evaluation and prevention are two important functions in all engineering disciplines. The Materials Specialist is one who plays a key role in the analysis of failures. This can be with respect to a specific module or service that fails in service or even if failure happens in the manufacturing or production process. Whatever the case may be, it is important to determine the cause of failure to prevent it from recurring. Diagnosing the problem can also help to increase the performance of the device, part, or even the entire structure.

Prognostic technology is a type of testing involving “proactive diagnostics, active reasoning and data-driven and model-based prognostic algorithms for completing a prognostic analysis.”

Engineering Materials in the industry was prone to failing pre-maturely in the case that the design was improper or the selection of supplies was wrong. This type of failure usually adds more cost to the project and so must be prevented as much as possible by using the “Failure Analysis Technique” also known as a Failure Investigation.

Failure investigations and analyses must always first identify the type of failure first before determining the root cause of it. Following this, corrective action should be taken to prevent further failures of this type.

In several cases, the importance of factors that have contributed to the failure must be assessed and based on this, there may be necessity to develop innovative experimental techniques. Additionally, one may have to exploring new and unfamiliar disciplines of engineering and science. A complex accident investigation such as those carried out in aircraft accidents involves several experts from different field of engineering, metallurgy, and other sciences. This short course helps specialists such as maintenance and inspection engineers conduct a failure investigation of the metallic components. During this procedure, there will be several discussions and discoveries related to revealing the form failure, identifying the root cause, as well as remedial procedures to prevent this.

Failure analysis of safety-critical and mission-critical equipment that is used on the field requires failure data collection as well as statistical analysis. Both of these are directly related to different reliability activities. Data collection must start from the very beginning, from stages of system design and move on to follow the product through its entire life cycle. It is important for both suppliers and users to perform detailed tracking as well as analysis of all equipment malfunctions and failures.

The final step in failure analysis is the finalising of corrective procedures based on whatever engineering data has been collected. The benefits of such procedures will become apparent to manufacturers as the number of failures start decreasing in the manufacturing line as well as in the field.