Whether your company is an OEM or vendor, when a part fails your reputation is on the line!
Most lab will provide data regarding the following questions:
How did it fail?
Materials fail by a variety of mechanisms, or modes, which exhibit distinct microscopic features. Typical failure modes include fatigue, brittle or ductile overload, corrosion, wear, hydrogen embrittlement, stress corrosion cracking, creep, and environmental degradation. MAI engineers are experts in identifying failure modes using the latest in stereo optical microscopy, high magnification SEM analysis and microstructure analysis.
Why did it fail?
Variations in failure mode result from material characteristics, manufacturing processing history, design, service conditions, or a combination of these factors. We perform mechanical testing, chemical analysis, and other tests when appropriate to determine material characteristics. Hardness, microhardness, and microstructure analysis determine the manufacturing process history. EDS analysis is performed to identify corrosive environmental exposure, wear particles, or contaminants. Service stress is calculated and compared to material characteristics to discover deficiencies or misuse in service. MAI engineers review and analyze test results and service history to pinpoint the exact cause of failure
MAI acknowledges a third question:
What will prevent it from failing again?
Recommendations that prevent failures are easily determined, however, recommendations that are economical, practical, and compatible with your existing manufacturing process is another matter. MAI engineers apply experience and knowledge to provide solutions that will work for you. We are your partners and want to ensure successful implementation of a recommended change.
We believe in answers not just numbers! We know a true failure analysis must answer ALL 3 critical questions to resolve your credibility with you customers.
What is included in a full failure analysis?
- A visual inspection and photos of the item as it is received by MAI.
- Sectioning the sample for other testing
- Scanning Electron Microscopy
- Chemical Analysis
- Hardness testing
- Making Micros for microhardness or metallography
- Metallography
- Tensile testing
- Charpy V-Notch testing
- Engineering time to produce a report to include all the data collected from the various tests and the engineer’s suggestions to prevent future failures
Results
The fully documented report, with our recommendations, is reviewed by multiple MAI team members and emailed upon completion of our analysis. our reports clearly explain our findings and recommendations in technically precis, but easily understandable terms. MAI team members are available to answer questions and discuss reports by phone, email, or Teams meeting.