Introduction and Need for Failure Analysis - Full Detailed Explanation
1. Introduction to Failure Analysis
Failure analysis is a systematic, scientific process used to investigate the cause of a failure in a
component, material, structure, or system. This failure could be sudden or progressive and may
involve physical breakdown, malfunction, or degradation over time.
Definition:
Failure Analysis is the process of collecting and analyzing data to determine the root cause of a
failure, with the objective of preventing it from happening again.
Failures are not merely breakdowns; they are learning opportunities that reveal critical flaws in
design, manufacturing, materials, or operation.
2. Types of Failures
Understanding the categories of failure is the first step in analysis:
Mechanical - Fracture, fatigue, overload (e.g., broken gear tooth)
Thermal - Deformation or cracking due to heat (e.g., turbine blade failure)
Chemical - Corrosion, oxidation (e.g., rusted pipeline)
Electrical - Short circuits, insulation breakdown (e.g., transformer failure)
Human/Operational - Misuse, poor maintenance (e.g., crane collapse due to overload)
3. Failure Analysis Process - Step-by-Step
Step 1: Collection of Background Data
- Component details (design, material, manufacturing method)
- Operating conditions (load, temperature, environment)
- Failure history (when, how, and what happened)
Step 2: Visual Inspection
- Surface examination
- Check for deformation, cracks, discoloration, wear, or corrosion
Step 3: Non-Destructive Testing (NDT)
- Methods like Ultrasonic Testing (UT), Radiography, Magnetic Particle Testing, Dye Penetrant
- Helps to detect internal flaws without damaging the part
Step 4: Material Analysis
- Metallography: Study of grain structure under microscope
- Chemical analysis: Check composition using spectrometers
- Hardness, tensile, and impact tests
Step 5: Fractography
- Examination of fracture surfaces under a Scanning Electron Microscope (SEM)
Step 6: Root Cause Determination
- Tools: Fishbone diagrams, Failure Mode and Effects Analysis (FMEA), 5 Whys
Step 7: Corrective Actions and Recommendations
- Design/process improvements, better maintenance
4. Need for Failure Analysis - Why It Is Essential
a) Safety Assurance - Prevent catastrophic failures (e.g., aviation, nuclear)
b) Reliability Improvement - Increases component life and trust
c) Cost Savings - Reduces repair, downtime, legal, and recall costs
d) Legal & Insurance Evidence - Determines liability and provides proof
e) Process & Design Optimization - Continuous improvement in design and production
f) Quality Control - Detect and prevent defects during manufacturing
g) Customer Satisfaction - Builds brand reputation
5. Real-World Examples of Failure Analysis
Case 1: Tacoma Narrows Bridge Collapse (1940)
- Cause: Aeroelastic flutter due to wind resonance
Case 2: Aloha Airlines Flight 243 (1988)
- Cause: Fatigue cracks in fuselage skin
Case 3: Space Shuttle Challenger (1986)
- Cause: O-ring failure at low temperatures
6. Conclusion
Failure analysis is not about assigning blame, but about learning and improving.
It ensures safety, reliability, and cost-efficiency in engineering systems.
