Failure analysis and prevention

Failure analysis is not just about a broken or cracked component. Failures can manifest from mechanical loading, corrosion, wear (sliding wear, erosion), thermal effects, electrical loading, etc. Low manufacturing yields are also a type of failure. This is a multidisciplinary process which considers the design, operating environment, materials, and manufacturing process. With our background in materials science, mechanical engineering, and chemistry, we can work with your organization to identify root cause for a failure. Understanding failure mechanisms is key to success. These are team projects. The process can be formalized by several methods.  We are most familiar with the fault tree and Ishikawa diagram approaches. The following sections describe in more detail our experience in corrosion, wear (tribology) and fracture.

Materials science and metallurgical consulting. Active sites (anodes) are stained blue and cathodic sites are pink in a ferroxyl indicator test.
Active sites (anodes) are stained blue and cathodic sites are pink in a ferroxyl indicator test.
Materials science and metallurgical consulting. Nomarski DIC image of corroded and worn electrical contact.
Nomarski (DIC) Image of sliding wear and corrosion on an electrical contact.
Materials science and metallurgical consulting. Torsional failure of center drill. Optical micrograph.
Torsional failure of center drill. Optical micrograph.

Contact us to see how REXP2 Research can help your organization with failure analysis and prevention.