Failure Analysis and Root Cause Determination

Failure analysis is the process of collecting data and analyzing it to determine the root cause of a failure called?

Examples of harsh environments that commonly induce failure include corrosive environment, high temperature environment

Stress, impact, and frictional loading are examples of operating conditions that frequently cause material failure.

The first critical step in failure prevention is to properly select the material or material system that will be used to construct the given system component.

examine and analyze (physical analysis, fractography, metallographic examination).

Before destruction for examination, it is important to photograph the failure in several angles for examination.

Loading situation can be used to evaluate the magnitude of strain.

Metallographic examination can reveal depth of hardening, grain size, phase present, non metallic inclusions

Crack initiation, fatigue striations, and fracture modes can be detected using SEM.

Microanalysis using energy dispersive X-ray spectroscopy (SEM/EDX) is used to analyze the phases, inclusions, and corrosion products.

Improper material selection, fabrication defects, and well heat treatments are all potential causes of failure in materials.

Correct design involves designing for maximum stress including safety factor and avoiding stress decrease.

Selecting appropriate materials does not depend on fatigue conditions, stress-rupture time, and temperature range of operation.

Casting may create gas porosity and cracks during the process.

Welding creates gas porosity and cracks.

Routine maintenance helps in lessening the possibility of a material failure due to extreme operating environments. True or False?