O’Donnell Consulting provides engineering troubleshooting on components and specialized equipment for critical service applications where the consequence of failure is catastrophic or costly. This includes thermal, mechanical, corrosion, materials/ weld, vibration, and fatigue, on re-occurring machinery problems, prototype issues, production line shutdowns, and field failures – designing solutions to ensure structural integrity.
We enjoy being challenged – assisting in the resolution of 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.
Materials & Weld EngineeringWeld overlay provides a surface protection which allows the substrate material to provide strength requirements to meet codes and standards, allowing the equipment to operate in a cost effective manner. We provide such weld overlay engineering to assist client needs. 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. Our weld engineering services include joint analysis, procedure development and qualification, process and filler-metal selection, to non-conformance and Code compliant resolutions - as well as developing weld repair procedures.
Metallurgical EvaluationsWe offer a full spectrum of metallurgical testing, performing corrosion investigations, surface condition studies, mechanical and fracture mechanics testing.
- Chemical and Mechanical Analyses
- Metallographic Examination
- Fractography (SEM and TEM)
- Accelerated Testing of Failure Modes
- Corrosion Testing
Fatigue/ Failure AnalysisFatigue 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 investigate the factors that contribute to structural failure - and provide practical solutions.
Forensic AnalysisOften, various technical issues may reach litigation. We provide forensic engineering services to predict how components behave under varying operating conditions, providing 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:
- Materials/weld issues on a coke oven battery
- Autoclave explosion
- Failure analysis on a pressure vessel used to make crystals for cell phones
- Failure analysis of a gas pipeline
- Weld crack investigation and repair of tube-to-tubesheet welds of a condenser
See Resume Summaries of our Engineering Team. Contact Us for a Free Quote.
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.
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 learning more in Engineering Design, Manufacturing and Construction, as well as Failure Analysis, then this book is a must have!