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Engineering Troubleshooting

Engineering Troubleshooting - O'Donnell ConsultingProviding engineering troubleshooting on equipment with issues including thermal, mechanical, corrosion, materials/ weld, vibration, and fatigue.

We have investigated prototype issues, production line shutdowns, and field failures – providing solutions which help our clients 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.
Failure Analysis of  Shaft


We have resolved many unique challenges in the energy, oil/gas, rail/transportation, manufacturing, and aerospace industries on components including:
  • Heat Exchangers
  • Pressure Vessels
  • Industrial Furnaces
  • Compressors
  • Welded Assemblies
  • Ductwork
  • Tanks
  • Shafts/ Bearings
  • Pumps / Valves
  • Piping / Supports
  • Bellows
  • Castings & Forgings
To see more components that we have worked on see Industries Served.


Materials & Weld Engineering

To ensure continued reliable service, we provide weld/ materials testing and analysis. Mechanical testing provides 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, as well as investigating non-conformance and Code compliance.

Metallurgical Evaluations

We 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 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 solutions.

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: Can't find what you're looking for? - use our Search Tool at the top of the Page. For a short listing of books, databases, and other engineering resources, see our Links page. See Resume Summaries of our Engineering Team.
Contact Us for a Free Quote.
Failure Analysis Bolt
Failure Analysis Shaft
Failure Analysis of Stud

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!

$49.95*

* Does not include shipping, handling or tax.