Failure Analysis Services

Failure Analysis ServicesFailure analysis is a critical aspect of product development and component/system improvement. O’Donnell Consulting performs failure analysis by investigating corrosion, vibration, fatigue, and other materials issues along with finite element analysis – developing solutions to ensure structural integrity.

Production line or other heavy machinery failures can be very costly or even catastrophic for a business – we save you time and money by resolving corrosion, vibration, fatigue, or other structural issues.

We have provided solutions on equipment in numerous applications including energy, oil/gas, mining, transportation, aerospace and manufacturing.

  • Pipelines, pumps, valves and compressors
  • Machinery, lift trucks, hydraulic presses, cranes, welded assemblies
  • Pressure vessels, reactors, dryers, and autoclaves
  • Heat Exchangers
  • Boilers, burners, and furnaces
  • Shafts, gears, bearings
Failure Analysis
Failure Analysis of a Weld
Failure Analysis of 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.

Root Cause Failure Analysis

Components not meeting their intended design life, or accidents and failures often result from factors including:
  • Design errors
  • Material imperfections
  • Manufacturing issues
  • Welding issues
  • Improper heat treatments
  • Misuse or abuse
  • Improper maintenance
  • Unforeseen operating conditions
  • Inadequate quality assurance
  • Inadequate environmental controls
In elevated temperature applications, complicated failure modes may occur, such as creep ratcheting, rupture, and creep fatigue. We have the expertise, technology, and experience to identify and quantify these failure modes - helping you understand the root cause and developing solutions 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
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. See Our Team to see resumes of our engineers. For a short listing of books, databases, and other engineering resources, see our Links page. Can't find what you're looking for? - try the Search Tool at the top of the page.

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 projects.

Failure Analysis of Axle
Handbook of Engineering Lessons Learned

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!


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