ODonnell Consulting

Failure Analysis Services

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.

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, Gearboxes, Bearings
  • Heat Exchangers, Steam Generators, HRSGs
  • Boilers, Burners, and Industrial Furnaces
  • Machinery, Lift Trucks, Hydraulic Presses, Cranes, Welded Assemblies
Failure Analysis
Failure Analysis of a Weld
Failure Analysis of Stud
We determine how materials and products fail, including mechanical integrity of equipment that has deteriorated due to corrosion, fatigue, damage,  abuse, and improper manufacture.

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.

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.

See also:
>> Failure Analysis & Redesign of a Fracking Pump
>> Failure Analysis on Cracked Tube to Tubesheet Welds on Chemical Reactor

>> Metallurgy
>> Stress Corrosion Mitigation
>> Publications
>> Links of Resources

While a tractor was cutting grass along an interstate, its left rear axle fractured, causing the left rear wheel to totally separate from the tractor. We were asked to investigate the cause of the failure. 

See Portfolio to read about several of our engineering challenges.

Failure Analysis of Axle
Handbook of Engineering Lessons Learned

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!


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