Materials/ Metallurgical Consulting

Materials & Metallurgical Solutions

Performing materials / metallurgical consulting – testing & analysis, and developing solutions to ensure structural integrity & compliance to Codes including ASTM, AWS, API and ASME.

Materials and metallurgical testing quantifies the properties of metals and is often used to determine whether it conforms to a required specification.

The primary benefits to materials investigations are (1) Ensuring the right materials/ properties for your application, or (2) In conjunction with chemical and other testing,  determining the cause of equipment failure.

Metallurgical Image of Weld Lack of Fusion

See Portfolio to read about our various projects. To see an interesting collage of projects, see the  Murals Page.

  • Recent Projects

  • Metallurgical Failure Analysis

    Visual and scanning electron microscopy (SEM) techniques are used to determine metallurgical failures due to manufacturing process problems, defects, contamination and corrosion.

    Equipment design life is often compromised through inadequate manufacturing processes such as welding and thermal/ transient conditions – and possibly high temperature environments. At elevated temperatures, creep and component strains occur, especially in welded and bolted joint connections.

    Defects often occur in welded, cast and forged parts. Parts with complex geometries often include crack starters, such as metallurgical notch effects – and thus testing is required. Read about the various types of Nondestructive Testing (NDT).

    Other metallurgical failures may result from vibration, thermal fatigue, thermal ratcheting, creep, fatigue, and fracture. We have 30+ years experience in engineering design, analysis, and materials science – determining locations of crack initiation sites, probable rates of propagation, modes of failure and fatigue life due to complex sources of dynamic loading.

    Examples Include:

    • Welded Assemblies
    • Pumps & Valves
    • Nozzles
    • Supports
    • Lifting Devices
    • Manufacturing
    • Petrochemical
    • Mining
    • Oil/ Gas
    • Power Generation
    • Pressure Vessels
    • Heat Exchangers
    • Piping
    • Condensors
    • Compressors


    Our team of experts come from diverse backgrounds, including power generation, materials & fabrication, fatigue/ failure analysis, and finite element analysis (FEA). FEA is often used along with materials / metallurgical analysis to identify failure modes.

    Interdisciplinary teams are essential for performing most failure analyses, since the root cause is rarely the result of a single variable. Understanding not only the metallurgical properties but also the environmental effects and stresses to a system or component is important in determining the cause of component failure.

    Once we identify component failure modes, we design modifications to ensure structural integrity and compliance to relevant codes.

    Our licensed Professional Engineers and Certified Welding Inspectors provide clients with support across the spectrum of welding and joining challenges – including code compliance, weld and joint inspection, and mechanical testing.

    Give us a call to discuss your engineering challenges.

    Materials/ Metallurgical Related Links

    >> Our Engineering Team
    >> Introduction to Metallurgy
    >> Engineering Troubleshooting
    >> Introduction to Fatigue Analysis
    >> Introduction to Corrosion
    >> Publications: Pressure Vessels, Fatigue, Weld Applications

    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

    Book Cover Image of Handbook of Lessons Learned

    (412) 835-5007

    Scroll to Top