Fatigue, Failure, and Fallout
When something goes wrong with a critical metallic component, manufacturers and engineers need the right answers, fast. Whether dealing with a broken fastener, a corroded pipeline, or premature wear, metallic failures pose risks that extend beyond isolated parts. They threaten your business’s profitability, productivity, safety, and reputation.
Failure analysis can serve as an essential first line of defense against shutdowns, legal issues, and potentially dangerous errors. Many failures are typically preventable through proactive testing and correctable through failure analysis.
Corrosion and fracture are the most common failures we see in our lab, often driven by design flaws, processing issues, and unexpected service conditions. These failures don’t just damage components; they can cause avoidable downtime, costly liability, and repeat issues if not properly diagnosed and remediated.
Conducting metallurgical analyses, such as microstructure, composition, corrosion, and/or hardness testing, is essential for quality assurance. These checks can help ensure that components meet design specifications and material requirements.
But what are the consequences of overlooking metallurgical testing? Imagine a scenario where a crew member performing routine maintenance on a wind turbine notices several broken bolt heads on the ground. To determine the root cause of the issue, the samples are sent to our lab for failure analysis. Scanning electron microscopy reveals an intergranular fracture surface morphology, indicating a hydrogen embrittlement failure mechanism. In this scenario, it would be determined that failure stemmed from an insufficient plating process. High-strength steel fasteners can experience delayed fractures within a few days after installation if they become embrittled by hydrogen. After zinc plating or galvanizing, the fasteners should have undergone a heat treatment at 350-400°F to allow the hydrogen produced during electroplating to diffuse out of the steel. Now, with this knowledge in mind, the client can identify the problematic batch of bolts and replace them before any costly or potentially dangerous accidents take place.
Examples like this serve as reminders of the potential hazards associated with neglected metal components. To help prevent such failures, operations managers can request testing materials to identify potential defects before they escalate into critical failures, and if failures occur, failure analysis to find solutions to problems. When manufacturers prioritize these practices, they contribute to a safer, more reliable world.
“It is important to be proactive by testing before new and revised designs are placed in service and by testing critical properties at the proper sampling frequency to help assure product uniformity. When failures occur, it is essential to properly analyze the failure to correctly identify the failure mechanism and contributing factors so that the cause of failure is understood and preventive actions are implemented.”
Ronald J. Parrington, P.E., FASM, Metallurgy & Failure Analysis Manager
Safety Starts Here: Let us Help Prevent the Next Metallurgical Failure
In those industries where precision and safety are paramount, the role of metallurgical testing cannot be overstated. ATS recognizes the high stakes involved when failure occurs. With decades of metallurgical experience and state-of-the-art labs, we have assisted hundreds of clients in swiftly and accurately identifying the root causes of metal failures, all while providing reliable documentation.
Our established failure analysis process consists of:
- Thorough visual and microscopic examinations
- Chemical and mechanical testing
- Identification of the failure mechanism, contributing factors, cause of failure, and preventive actions
- Actionable reports and expert consultations
Protect your operations, your people, and your bottom line. Schedule a consultation with one of our metallurgy experts today using our web request form or call us at (888) 287-5227.
