Conducting the failure examination

Conclusion Performing failure analyses is an exceptionally challenging and exciting job. The investigator must have a sound background in the areas that are central to testing and analytical work and must also be knowledgeable enough to know when to call on other fields of specialization that interface with the work. New problems are always encountered that tax the ingenuity of the investigator, and they will sharpen and expand ones skills if we are willing to go on learning. By the same token, analysis of failures by many investigators in the ferrous and nonferrous metal industries here and abroad has, over the years, expanded the practical knowledge for processing and product developments and also contributed to basic scientific insights. Those who frequently conduct failure examinations agree on several main points. Most failures could easily be prevented if certain well-documented precautions are taken. Many failures occur as a result of fatigue, and one or more of the following may play a decisive role: original design deficiencies, material inadequacies, machining or fabrication, imperfections, abuse or neglect, improper maintenance, improper repairs, and metallurgical factors such as decarburization. Heat-treatment irregularities are another major contributing factor in failures.