Materials/ Metallurgical Consulting

Performing materials / metallurgical consulting – including testing, analysis and solutions to ensure structural integrity, and compliance to codes including ASTM, NACE, 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 are (1) Ensuring the right materials/ properties for your application, or (2) In conjunction with corrosion and chemical 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 our  Murals Page.
  • Recent Projects

  •  Metallurgical Failure Analysis

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

    Often, equipment design life is often compromised through inadequate manufacturing processes such as welding, thermal/ transient conditions, and high temperature conditions. 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 modes of failure, crack initiation sites, probable rates of propagation, and fatigue life due to complex sources of dynamic loading.

    • Nickel Alloy Steels
    • High Temperature Alloys
    • Tool Steels
    • Stainless Steels
    • Carbon Steels
    • Alloy Steels
    • Titanium
    • Aluminum Alloys
    • Copper Alloys

    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 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 testing and 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 a material failure.

    Once we identify component failure modes, we perform 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.

    Can’t find what you’re looking for? Try our Search Tool.
    Give us a call – Let’s talk about your needs.

    Materials/ Metallurgical Related Links

    >> Our Engineering Team
    >> Introduction to Metallurgy
    >> Engineering Troubleshooting
    >> Introduction to Fatigue Analysis
    >> Failure Analysis Services
    >> Portfolio of Projects
    >> Publications – Heat Exchangers, Pressure Vessels, Fatigue, Weld Applications
    >> Links to Engineering Resources

    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

    (412) 835-5007

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