9-step Failure Analysis Process

Metallurgical failure analysis is the first step of the root cause analysis process. For failures during testing and use, a failure analysis is performed to determine the failure mode and failure mechanism of the failed item, whether any metallurgical characteristics of the failed item contributed to the failure, and the metallurgical reason for the failure. For quality problems, a failure analysis is performed to assess metallurgical characteristics of the problem item, whether they meet the item’s specifications, and the metallurgical reason for the problem. The information obtained from a failure analysis is then used to identify the root cause of the failure or quality problem
Below is a summary of our 9-step failure analysis processes
Needs Review. Every failure analysis project starts with a conversation with you and your engineering team to review the problem and collect background information. This is done by phone or internet meeting and usually takes 15 - 30 minutes. There’s no charge for this step. We’ll review photos and drawings of the problem component or material and discuss the circumstances of the problem. We will also discuss the project scope, the metallurgical analysis and samples required, and approximate cost. For the scope, it’s critical to have complete agreement on the problem to solve.
Identify the Project Approach. This is where I use my experience, training, and knowledge to identify the best path forward. This includes metallurgical analysis of components or metal stock. Selecting the appropriate metallurgical analyses and samples to examine is critical to get information that enables finding the cause of the problem and preventing it from reoccurring. The approach might also include review of technical literature and discussions with suppliers.
Project Quote. A project quote includes the project scope, the work to be performed, and the cost. After you approve the work we begin right away, and we meet or beat our timelines. We understand that failure analysis work is time sensitive.
Perform the Analyses. The metallurgical analyses are performed, and the data is collected and reviewed. The analysis information combined with the background information is used to identify the metallurgical cause of the problem and possible root causes.
Review data. We review the analysis findings with you and discuss possible root causes of the failure or problem. At this point your input is important. The metallurgical analyses results will indicate the conditions that cause the failure and whether there was anything metallurgically wrong with the metal. However, more background information is often needed to use the analysis to identify the root cause. Your knowledge about the item’s design, manufacturing, and use are important. This part is key - we won’t just give you a report and leave it to you to figure out how to use the information to fix your problem. We work with clients to help them use failure analysis results to understand how the failure or problem occurred, its root cause, and how to prevent it from reoccurring. This is what distinguishes us from other companies that offer failure analysis. We do more than just forensics - we help engineer solutions.
Written Report and Support. Once you have your reports and understand the findings we continue to support you throughout the implementation of the changes recommended.
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