Failure Analysis

Introduction to Failure Analysis

Failure analysis is the methodical process of identifying the cause of product failure and using it to prevent future failures. Failure analysis is a key component of product creation, improvement, and quality control processes. To define the failure and evaluate the failed material, a multidisciplinary set of mechanical, chemical, physical, and environmental investigations is employed. This helps to identify the underlying problem and offers a thorough remedy based on the findings. Failure analysis enables businesses to identify future product responsibility, avert financial losses, and meet product safety and compliance criteria. In a variety of sectors, including aerospace, energy, transportation, electronics, construction, medical devices, and consumer products, failure analysis is a common service used by manufacturers, commercial intermediaries, researchers, and insurance companies. Failure analysis is done to determine the cause of failure, usually with the aim of taking corrective action to fix the issue.

Failure Analysis Procedure

Failure analysis is done using a wide range of scientific instruments and methods, such as numerous varieties of microscopes, chemicals, spectrometers, and computer simulations. The type of research and instruments utilized depend on the failure's nature. Failure analysis may be applied to both products and processes.

Failure Analysis Tools and Methods

Failure analysis may be carried out at the design stage and at the field use stage of a product life cycle using various tools per the suitability of the project.

• Failure data collection using FRACAS (Failure Reporting, Analysis and Corrective Actions System)
• FMEA (Failure Modes and Effects Analysis)
• FMECA (Failure Mode, Effects and Criticality Analysis)
• FTA (Fault Tree Analysis)
• ETA (Event Tree Analysis)
• RCA (Root Cause Analysis)

The common methods used for failure analysis are visual inspection studies, chemical and contaminant analysis, metallurgical testing, mechanical testing, vibration testing, environmental testing, polymeric materials testing, electron microscopy, thermal analysis, corrosion testing, impact testing, fatigue testing among others.