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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.

This Learning Track has been developed by Dr. D. K. Dwivedi from IIT Roorkee for NPTEL. It is now accessible through Ansys Innovation Space courtesy of the partnership between Ansys and NPTEL, under the CC BY-SA license. For more details, visit https://nptel.ac.in/courses/112107241.

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1
Innovation Course

Introduction to Failure Analysis

This course covers the critical subject of failure analysis and prevention in engineering, with a particular focus on mechanical components. It delves into the conditions that constitute a component failure, such as inoperability, compromised saf...Read more

2
Innovation Course

Fundamental Sources of Failure: Manufacturing

This course covers the fundamental sources of failure in mechanical components and manufacturing processes, and how to prevent them. It delves into the role of extra stages in failures, the impact of imperfections in base metals, and ...Read more

3
Innovation Course

Industrial Engineering Tool for Failure Analysis

This course covers the comprehensive understanding of failure analysis and prevention in various systems. It starts with the exploration of fundamental sources of failure such as poor assembly, service conditions, and maintenance....Read more

4
Innovation Course

General Procedure of Failure Analysis: Introduction

This course covers the comprehensive understanding of product reliability and failure analysis. It delves into the importance of reliability in product design and how it is closely related to failure analysis. For instance, a pr...Read more

5
Innovation Course

General Procedure of Failure Analysis: NDT, DT and Macroscopy

This course covers the comprehensive study of failure analysis and prevention in engineering components. It begins with an exploration of the importance of failure analysis, the general practices and procedures involved...Read more

6
Innovation Course

General Procedure of Failure Analysis: Macroscopy and Metallurgy

This course covers the comprehensive procedure of failure analysis and prevention, focusing on the macroscopic and microscopic examination of fracture surfaces. It delves into the importance of identifying the locat...Read more

7
Innovation Course

Determination of Fracture and Application of Fracture Mechanics

This course covers the comprehensive study of fracture analysis and prevention. It provides an in-depth understanding of different fracture types such as dimple fracture, cleavage fracture, and intergranular fractur...Read more

8
Innovation Course

Failure Analysis of Welds

This course covers the extensive process of failure analysis and prevention, focusing on various aspects such as the steps involved in failure analysis, the method of reporting, analysis of welded joints, and the comprehensive process of failure analysi...Read more

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