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Engineering Troubleshooting

O'Donnell Consulting engineering troubleshootingO’Donnell Consulting provides engineering troubleshooting services on issues such as re-occurring machinery problems, prototype issues, production line shutdowns, and field failures. We investigate thermal, mechanical, corrosion, materials/ weld, vibration, and fatigue – designing solutions to ensure structural integrity. We resolve simple to complex issues, helping you save time, money, and reputation.

We were asked to investigate the failure of a splined clutch power transmission shaft. This macrophotograph at 7x shows a broken tooth with simultaneous fatigue initiation at the root radius of each side of the tooth. Reverse loading ultimately lead to fatigue fracture.

To see more of the projects we have worked on, see Portfolio.
Failure Analysis Shaft

We have resolved many unique challenges in the energy, oil/gas, rail/transportation, manufacturing, and aerospace industries.
  • Thermal
  • Mechanical
  • Buckling
  • Vibration
  • Fatigue
  • Creep
  • Creep Fatigue
  • Corrosion
  • Fracture
  • Weld Cracking
  • Weld Distortions

Materials & Weld Engineering

To ensure continued reliable service, we provide materials testing and analysis services. Mechanical testing and finite element analysis provide data which are evaluated in such terms as ductility, strength, toughness, corrosion resistance, and fatigue properties of the as-fabricated materials. We also provide weld engineering services, ranging from joint analysis to procedure development and qualification, process and filler-metal selection, to non-conformance and Code compliant resolutions. We are quite familiar with ASME, AWS, API and other design codes. In addition, we design weld repairs and weld overlays.

Metallurgical Evaluations

We offer a full spectrum of metallurgical testing, performing corrosion investigations, surface condition studies, mechanical and fracture mechanics testing. Our testing includes:
  • Chemical and Mechanical Analyses
  • Metallographic Examination
  • Fractography (SEM and TEM)
  • Accelerated Testing of Failure Modes
  • Corrosion Testing

Fatigue/ Failure Analysis

Fatigue is one of the key contributing factors to the degradation of aging components. Fatigue failures occur when these structures are subjected to cyclic stresses and strains over time. This leads to the development of micro-cracks in the most highly strained locations, which subsequently propagate until the component fails. We understand the factors that contribute to structural failure - and provide practical solutions.

Forensic Analysis

Often, various technical issues reach litigation - that's where we perform forensic services. We perform calculations - from simple to complex finite element analysis - to predict how components behave under varying operating conditions, and provide results that are easily understood by Judges and Juries. We have testified in State, Federal, and International Courts, in both defendant and plaintiff cases. Some of our projects include:
  • Autoclave explosion
  • Fire/ explosion investigations on well sites
  • Failure analysis of a gas pipeline
  • Weld crack investigation and repair of tube-to-tubesheet welds of a condenser
  • Failure analysis on a pressure vessel used to make crystals for cell phones
  • Weld crack investigation and repair of tube-to-tubesheet welds of a condenser
  • Construction/ weld issues on a coke oven battery

Can't find what you're looking for? - use our Search Tool at the top of the Page.
For a short listing of books, databases, and other engineering resources, see our Links page. Find resume summaries of our engineers here.

Failure Analysis Bolt
Failure Analysis Shaft
Failure Analysis of Stud

We evaluate structures that suffer degradation as a result of fabrication or service-induced defects. Our services include metallurgical evaluations, weld engineering support, materials selection, and root cause failure analysis.

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Get the Latest Book
by Dr. William O’Donnell, PhD, PE : Founder and President of O’Donnell Consulting Engineers, Inc.

Learn from the experience of others. Especially when one such “other” is Dr. William O’Donnell, PhD, PE, Founder and President of O’Donnell Consulting Engineers, Inc., and ASME “Engineer of the Year” - his 50 years of experience in analysis of components including fatigue and fracture safety evaluations and failure analyses are now comprised in this volume. If you are interested in the fields of Engineering Design, Manufacturing and Construction, as well as Failure Analysis, then this book is a must have!

$49.95*

* Does not include shipping, handling or tax.

 
Failure Analysis Bolt
Failure Analysis Shaft
Failure Analysis of Stud

We evaluate structures that suffer degradation as a result of fabrication or service-induced defects. Our services include metallurgical evaluations, weld engineering support, materials selection, and root cause failure analysis.

O'Donnell Consulting engineering troubleshootingO’Donnell Consulting provides engineering troubleshooting services on issues such as re-occurring machinery problems, prototype issues, production line shutdowns, and field failures. We investigate thermal, mechanical, corrosion, materials/ weld, vibration, and fatigue – designing solutions to ensure structural integrity. We resolve simple to complex issues, helping you save time, money, and reputation.