Metallurgy/ Materials Consulting

O'Donnell Consulting - Materials troubleshooting

O’Donnell Consulting performs materials, weld and metallurgical consulting services, including testing, failure analysis, and repair. We have been performing these services for over 40 years, helping clients solve their structural integrity issues, extending fatigue life, and improving component performance.

Manufacturing processes, design configuration, corrosion, vibration, thermal fatigue, thermal ratchetting, creep, fatigue, and fracture all play a part in structural integrity. We have the experience in design, stress analysis, and materials science to minimize size and cost while maintaining part performance and design life. Design life is often compromised through inadequate manufacturing processes such as welding, thermal/ transient conditions, and high temperature conditions. At elevated temperatures, creep, and component strains occur, especially in welded and bolted joint connections.

  • (Mechanical and corrosion) testing to standards including ASTM, ASME, AWS and API
  • Weld Process Development
  • Certified Weld Inspection
  • Weld Analysis and Repair
  • Chemical Analysis
  • Coatings Analysis
  • X-Ray Spectroscopy
  • Electron Spectroscopy
  • Image Analysis
  • Chemical Analysis
  • Fracture Analysis
  • Fatigue Analysis
  • Fatigue of Welded Joints
  • Creep Rupture Analysis
  • Crack Growth Rate Analysis
Metallurgical Analysis

We perform design, analysis and troubleshooting of welded and non-welded structures - providing materials testing, metallurgy, remaining life assessments, and failure analysis of boilers, turbines, pumps, and valves among many other components, including:

Defects often occur in welded, cast and forged parts. Parts with complex geometries often include crack starters such as metallurgical notch effects. We provide nondestructive testing (NDT) to determine quality and serviceability. The various types of NDT include:

Ultrasonic Testing (UT)
This method uses a transducer to introduce high frequency sound waves into a material to detect imperfections. In the pulse echo technique, reflections (echoes) from internal imperfections or geometrical surfaces are returned to a receiver, providing images of a defect.

Magnetic Particle Testing (MT)
This method induces a magnetic field in a ferromagnetic material and then iron particles are applied to the surface of the test piece. When a surface or subsurface discontinuity interrupts the induced magnetic field, a leakage field forms above the discontinuity. Iron particles will form an outline of the leakage field revealing its location, size and shape.

Eddy Current Testing (ET)
Using this method, electrical currents (Eddy Currents) are generated in a conductive material by a changing magnetic field. Relevant indications are noted when the flow of eddy currents is interrupted by a defect.

Penetrant Testing (PT)
This method involves coating the test specimen with a visible or fluorescent dye. A developer is then applied to draw out the penetrant left behind in surface defects. With fluorescent dyes, ultraviolet lights are used to find the surface imperfections.

We are a team of experienced, multi-disciplined engineers, with expertise in materials, fabrication, and finite element analysis. Our engineers publish technical reports, develop patents, and are active in Codes and Standards Committees including the American Society of Mechanical Engineers (ASME), The American Welding Society (AWS), the National Association for Corrosion Engineers (NACE), and the American Nuclear Society (ANS).
We have been providing solutions for over 40 years to the aerospace, power generation, manufacturing, automotive, consumer products, materials handling, and construction industries.

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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!


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