Failure Analysis

A failure is defined as “the inability of a component, machine, or process to function properly.” Failures come in all shapes and sizes; they can be individual parts, entire machines, or a process. Specific levels of failure causes can be physical, human, latent, or root. The physical failure of materials includes distortion or undesired deformation, fracture, corrosion, and wear. Failures are also specific to an industry and the specific requirements of that industry. It is necessary to be knowledgeable about defining the requirements of the failure at hand.

Every product or process has modes of failure. An analysis of potential failures helps manufactures and designers focus on and understand the impact of potential risks and failures. Analyzing failures is a critical process. The process is complex, draws upon many different technical disciplines, and uses a variety of observation, inspection, and laboratory techniques. One of the key factors in properly performing a failure analysis is keeping an open mind while examining and analyzing the evidence to foster a clear, unbiased perspective of the failure.

The principal task of a failure analyst during a physical-cause investigation is to identify the sequence of events involved in the failure. To determine the cause of materials failure, one must consider the active stressors, which include mechanical, chemical, electrochemical, thermal, radiation and electrical factors. Several systematic methodologies have been developed to quantify the effects and impacts of failures. For example, the Failure Modes & Effects Analysis (FMEA) methodology is based on a hierarchical, inductive approach to analysis, the analyst must determine how every possible failure mode of every system component affects the system operation. FMEA has evolved into a powerful tool that can be used by design engineers during all product-development phases to enhance product safety and reliability. Other common failure analysis techniques include Cause-Consequence Analysis, Failure Modes, Effects and Criticality Analysis (FMECA), Fault Tree Analysis (FTA), Hazard & Operability Analysis (HAZOP).

Matexcel’s failure analysis services range from failure investigation to failure prevention. Such as conducting analyses and troubleshooting on failed engineering components, powder plants, consumer and retail goods that fail or do not perform as expected. Our effective and extensive breadth of services can benefit both of your product and process development, including prevent product malfunctions, insure product life, insure product quality, achieve process reliability, prevent safety or environmental hazards, prevent customer dissatisfaction.

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