ODonnell Consulting

Failure Analysis Services

We provide failure analysis services through a multi-disciplinary method of investigating materials and operational issues – often with finite element analysis– developing solutions to ensure structural integrity, preventing future occurrences.

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

  • Pipelines, Pumps, Valves, Compressors
  • Pressure Vessels, Reactors, Dryers, and Autoclaves
  • Shafts, Blades, Gearboxes, Gears, Bearings
  • Heat Exchangers, Steam Generators, HRSGs
  • Boilers, Burners, and Industrial Furnaces
  • Machinery, Lift Trucks, Hydraulic Presses, Cranes, Welded Assemblies

We determine how materials and products fail, including mechanical integrity of equipment that has deteriorated due to corrosion, fatigue, damage, abuse, and improper manufacture.   Contact Us for a free quote.

Recent Projects

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 improving safety and lowering operating costs.

A few examples include:

  • Heat Exchangers
  • Bellows
  • Piping
  • Condensors
  • Reactors
  • Manufacturing
  • Petrochemical
  • Mining
  • Oil/ Gas
  • Power Generation
  • Refractory
  • Ductwork
  • Compressors
  • Heaters
  • Welded Assemblies

Metallurgy/ Testing
We offer a full spectrum of metallurgical testing to evaluate the root cause of component failure, performing corrosion investigations, surface condition studies, mechanical testing, and evaluations of weldments. This 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.

Related Services:
>> Engineering Troubleshooting
>> Weld Troubleshooting/ Consulting
>> Introduction to Corrosion
>> Publications
>> Links of 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