The Applied Technical Services Family of Companies (ATS FoC) performs casting failure analysis to identify root causes of defects in casting components, helping clients improve product quality and operational efficiency.
Casting is a manufacturing process where molten metal is poured into a mold and solidified into a specific shape. Cast components are widely used in engine blocks, pump and valve bodies, structural and aerospace applications, and various industrial machinery parts that demand strength and durability.
What are Common Casting Defects and Failure Modes?
Casting defects and failures can compromise mechanical performance or cause early failure. These issues may result from manufacturing or service conditions. ATS investigates a full range of casting defects and failures, including but not limited to:
- Porosity, Gas, Shrinkage
- Cracks and Fractures
- Inclusions
- Hot Tearing, Hot Cracking, Heat-Treatment Issues
- Cold Shut and Misruns
- Segregation
- Abrasion and Fatigue
- Corrosion or Stress Corrosion
- Overload or Impact Damage
- Material Composition Errors
- Manufacturing Defects
- Service-Induced Failures
Our team of failure analysis experts combines testing and inspection methods to determine the why behind cast component failures during manufacturing, assembly, testing, or field service.
How Can Root Cause Analysis Help Prevent Future Failures?
By identifying the true cause of failure, our root cause analysis services enable our clients to implement effective corrective actions, optimize manufacturing processes, improve quality control, and prevent future failures. We identify root causes of casting failures by evaluating each component’s entire lifecycle, including material selection, manufacturing processes, post-processing treatments, and service conditions.
ATS utilizes advanced analytical tools and testing capabilities in both laboratory and field settings to thoroughly characterize casting defects and failures using methods such as:
- Liquid Penetrant Testing (PT)
- Visual and Macroscopic Examination
- Radiographic (X-ray) Inspection
- Optical and Scanning Electron Microscopy (SEM)
- Metallurgical Analysis
- Chemical Composition Analysis
- Mechanical Testing
- Non-Destructive Testing (NDT)
- Ultrasonic Testing (UT)
- Magnetic Particle Testing (MT)
Our comprehensive approach, aligned with ASTM, ASME, ISO, and industry standards, enables us to pinpoint both primary and contributing failure mechanisms.
Partner with ATS
Our comprehensive approach, aligned with ASTM, ASME, ISO, and industry standards, enables us to pinpoint both primary and contributing failure mechanisms. Operating under an ISO 9001:2015-registered quality management system and supported by multiple ISO/IEC 17025:2017 accreditations, ATS leverages extensive metallurgical engineering and failure analysis experience to help clients quickly and accurately identify root causes of casting defects. Our team delivers actionable insights to improve product integrity, reduce downtime, and enhance safety.
Contact Us
Ready to submit a component for evaluation? Partner with ATS for casting failure analysis. Complete our web form or call +1 (888) 287-5227 to get started today.
