General procedure of failure analysis: Question for analysis — Lesson 1

This lesson covers the comprehensive process of failure analysis and prevention. It delves into the steps involved in failure analysis, including information collection, preliminary examination, non-destructive testing (NDT), destructive testing (DT), macroscopy, microscopy, metallography, chemical analysis, fracture mechanism determination, and simulated service testing. The lesson emphasizes the importance of integrating the results from these different stages to formulate conclusions about the primary causes of failure. It also highlights the significance of a questionnaire in failure analysis to avoid overlooking any aspects and to guide the areas of investigation. The lesson further discusses the questions that need to be asked at the end of the failure analysis to ensure all aspects have been considered.

Video Highlights

00:59 - Importance of information collection in failure analysis.
04:12 - Explanation of the role of a questionnaire in failure analysis.
14:38 - Explanation of the importance of identifying the temperature at the time of failure.
25:26 - Discussion on the importance of identifying the role of improper assembly in failure.
28:33 - Discussion on the importance of identifying the possibility of design improvement.

Key Takeaways

- Failure analysis involves a series of steps including information collection, various types of testing, and result integration.
- A questionnaire is crucial in failure analysis to ensure no aspects are overlooked and to guide the areas of investigation.
- At the end of the failure analysis, certain questions need to be asked to ensure all aspects have been considered, such as the sequence of events leading to the failure, the location of fracture initiation, the role of stress risers, and the duration of crack presence before fracture.
- The type and intensity of loading, the role of wear and corrosion, the conformance of the material with the specification, and the role of heat treatment and improper manufacturing are all factors to be considered in failure analysis.
- The possibility of abuse in service, the perfection of the design, and the potential for similar failures in the future are also important considerations.