Failure Analysis and Prevention

This learning track covers the comprehensive study of failure analysis and prevention in engineering. It begins with an exploration of the conditions that constitute a component failure, such as inoperability, compromised safety, and reliability. The track delves into the four broad categories of mechanical component failures and their fundamental causes, including design, material, manufacturing, and service conditions. For instance, a well-designed automobile can fail if the incorrect lubricant is used. The track further explores the importance of systematic investigation to identify the root causes of failures. It also highlights the role of extra stages in failures, the impact of imperfections in base metals, and the importance of proper manufacturing procedures. For instance, the track provides a case study on the failure of a connecting rod due to metallurgical heterogeneity and how proper heat treatment and control of microstructure can prevent such failures. The track concludes with a detailed explanation of the application of industrial engineering tools like the Pareto diagram, Fishbone diagram, Failure Mode and Effect Analysis (FMEA), and Fault Tree Analysis (FTA) for systematic failure analysis.