ODonnell Consulting

Engineering Troubleshooting

Engineering Troubleshooting - O'Donnell Consulting
Our engineering troubleshooting services provide repair solutions to operational problems on equipment – keeping our clients compliant to AWS, API, ASME and other Codes.

Operational problems may include thermal, mechanical, corrosion, materials/ weld, vibration, and fatigue issues on power and process equipment including pressure vessels, heat exchangers, piping and compressors. We have solved problems on prototypes, production lines, and field failures – enabling our clients to save their time and reputation, and reduce life cycle costs.

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.   Contact Us for a free quote.

Image of Failed Transmission Gear

Recent Projects

Materials & Weld Engineering

To ensure continued reliable service, we provide materials & weld testing and analysis. Mechanical testing provides ductility, strength, toughness, corrosion resistance, and fatigue properties of the as-fabricated materials. Such testing assists in the prediction of when and how materials and assemblies will fail under various loading conditions. Our weld engineering services include joint analysis, procedure development and qualification, process and filler-metal selection, as well as investigating non-conformance and Code compliance. We provide assistance to keep you in accordance with AWS, ASME and other relevant Codes.

A few examples include:

  • Petrochemical
  • Mining
  • Transportation
  • Aerospace
  • Energy
  • Steam Generators
  • Superheaters
  • Evaporators
  • Piping

Metallurgical Evaluations

We offer a full spectrum of metallurgical testing including corrosion investigations, surface condition studies, mechanical and fracture mechanics testing. Read more about Metallurgy or Corrosion.

  • 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 investigate the factors that contribute to structural failure – and provide practical repair solutions to get you fully operational.

Forensic Analysis

Often, various technical issues may reach litigation. We provide forensic engineering services to predict how components have failed – 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 have included:


Related Links:
>> Materials/ Metallurgy Consulting
>> Weld Troubleshooting/ Consulting
>> Introduction to Fatigue
>> Links to Engineering Resources
>> Publications – Heat Exchangers, Pressure Vessels, Fatigue, Elevated Temperature

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!


* Does not include shipping, handling or tax

Handbook of Lessons Learned