Failure Analysis and Residual Life Estimation

Our Approach to Failure Analysis

Comprehensive Methodology

Our failure analysis process is designed to identify not just what failed, but why it failed and how to prevent similar failures in the future. We employ a systematic methodology that includes:

• Detailed visual inspection and documentation of the failed component
• Non-destructive testing to identify potential failure modes
• Metallographic examination to analyze microstructure
• Advanced chemical analysis to identify material composition
• Mechanical testing to determine material properties
• Fracture mechanics analysis to understand crack propagation

Advanced Testing Equipment

Our laboratory is equipped with state-of-the-art testing equipment that allows us to conduct detailed analyses of failed components. Our equipment includes:

Scanning Electron Microscopy (SEM)

High-resolution imaging for detailed surface analysis and fracture characterization

X-Ray Diffraction (XRD)

Analysis of crystalline phases and residual stresses in materials

Spectrometry

Precise determination of chemical composition of metallic materials

Mechanical Testing

Determination of tensile, compression, hardness, and impact properties

Residual Life Estimation

Beyond identifying the cause of failure, our team specializes in estimating the remaining useful life of components. This service is particularly valuable for:

• High-value components nearing their design life
• Critical infrastructure where unexpected failures can lead to significant downtime
• Components operating in harsh or unpredictable environments
• Planning maintenance schedules and replacement strategies

Our residual life estimation combines material science, stress analysis, and operational data to provide accurate predictions of remaining component life.

Case Studies

Industrial Boiler Tube Failure

A power generation facility experienced repeated failures of boiler tubes, leading to unplanned shutdowns and significant production losses. Our analysis identified stress corrosion cracking as the primary failure mechanism, related to unexpected chemical conditions in the feedwater.

Result: Implementation of our recommended changes to water chemistry and tube material selection eliminated the recurring failures, saving the client an estimated $1.2 million annually in lost production.

Heavy Equipment Shaft Failure

A mining company experienced catastrophic failure of a critical component in their ore processing equipment, resulting in extended downtime. Our analysis revealed fatigue failure originating from a design feature that concentrated stress beyond safe levels.

Result: We redesigned the component with improved geometry and material selection, extending its service life by over 300% and preventing further unplanned shutdowns.

Our Team

Our failure analysis team is led by experienced metallurgists, materials scientists, and engineers with decades of combined experience in industrial failure investigation. Each team member brings specialized expertise in different aspects of materials behavior and analysis techniques.

Ready to work with our experts?

Contact us today to discuss your failure analysis needs or to schedule a consultation with our team. We're ready to help you identify the root causes of failures and develop effective solutions.

Contact Our Team