Failure Analysis

O'Donnell Consulting Failure AnalysisO’Donnell Consulting performs failure analysis by combining materials and metallurgy with state-of-the-art finite element analysis, to determine the precise root cause.

We save you time and money by resolving problems in corrosion, vibration, fatigue, or other structural issues – investigating failures and providing solutions on equipment in numerous industries including energy, oil/gas, mining, transportation, aerospace and manufacturing.

Our work has included:

  • Pipelines, pumps, valves and compressors
  • Shears, lift trucks, hydraulic presses, cranes, machinery
  • Pressure vessels, reactors, dryers, and autoclaves
  • Landing gears, actuators and flight controls
  • Turbines/ blades
  • Boilers, burners, and heat exchangers
  • Shafts, gears, bearings

To see a partial list of equipment we have worked on, see Components.

Accident/ Failure Analysis
Accidents, structural failures, or even components not meeting their intended design life often result from design and/or material imperfections, problems in manufacturing / assembly, component misuse, or corrosion. In elevated temperature applications, complicated failure modes may ocurr, such as creep ratcheting, rupture, and creep fatigue.

  • We have the expertise, technology, and experience to identify and quantify these failure modes.
  • We help you understand the root cause and perform design-of-repair to prevent costly recurrences, thus lowering operating costs and improving safety.

Metallurgy/ Testing

We offer a full spectrum of metallurgical testing in conjunction with our engineering analysis tools to evaluate the root cause of component failure. We perform corrosion investigations, surface condition studies, mechanical and fracture mechanics testing, and evaluations of weldments.
Our testing includes:

  • Chemical and mechanical analyses
  • Metallographic examination
  • Fractography (SEM and TEM)
  • Accelerated testing of failure modes
  • Material testing
  • Corrosion testing
Failure Analysis
Analysis Weld
Failure Analysis Stud
We determine how materials and products fail, including mechanical integrity of equipment that has deteriorated due to corrosion, fatigue, damage,  abuse, and improper manufacture.

If and when it becomes necessary to present the facts in court, we supply 3-D animations, cutting-edge computer graphics, and multimedia presentations to accompany our expert testimony, clearly demonstrating the issues for Judges and Juries to easily understand. To read more, see Expert Witness.

We also provide Fire/ Explosion Investigations. Click here to see resume summaries of our senior engineers. See What We Do to read about our full range of engineering services. Can't find what you're looking for? - try our Search Tool at the top of the page.

Call or Submit a Query to talk about your technical issues.

While a tractor was being used to cut grass along an interstate, its left rear axle fractured, causing the left rear wheel to totally separate from the tractor. We were asked to investigate the cause of the failure. 

See Portfolio to read about our previous cases.

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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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