Images of Failed Components

Performing engineering failure analysis services – resolving materials, weld, vibration, fatigue, and other operational issues to prevent recurrence. Ensuring structural integrity, and maximizing equipment reliability & controlling costs for owners/ users.

We are a team of engineers, metallurgists & weld experts investigating the root cause of structural and weld failures due to thermal/ transients, vibrations, thermal fatigue and more.

Applications include aluminum, stainless steels, titanium, nickel based and exotic alloys used in aircraft, petrochemical plants, industrial machinery, automotive components, medical equipment, ASME boilers and pressure vessels and oil/gas pipelines. Other applications include:

For a more comprehensive list, see Industries Served.

Failure Analysis: Stud Image
Failure Analysis: Crack Image
Failure Analysis: Weld Image

Although many components fail due to fatigue failure – quite often there are other factors involved, including coatings, corrosion, damage, abuse, and improper manufacture. 

Contact Us to learn more.

  • Recent Projects

  • Root Cause Failure Analysis

    Components not meeting their intended design life, or accidents and failures typically occur due to fatigue, but other factors may include:

    • Design Errors
    • Material Imperfections
    • Manufacturing Issues
    • Welding Issues
    • Improper Heat Treatments
    • Fatigue / Fracture
    • Misuse or abuse
    • Improper Maintenance
    • Unforeseen Operating Conditions
    • Inadequate Quality Sssurance
    • Environmental Issues (Vibration, Corrosion, etc.)

    Interdisciplinary teams are essential for performing most failure analyses, since the root cause is rarely the result of a single variable. In performing metallurgical failure analysis, we investigate operational issues, environmental factors, load paths and stresses to a system or component.

    Once we identify potential component failure modes, we recommend inspection methods/ intervals, and design solutions to reduce the likelihood of future failures.

    In elevated temperature applications, complicated failure modes may occur, such as creep ratcheting, rupture, and creep fatigue. Our engineers 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.

    Codes and Standards

    We have assisted clients in various industries – keeping them compliant to engineering codes and standards including:

    • ANSI
    • AISC
    • ASTM
    • AWS
    • API
    • ASME
    • ASCE
    • NBIC
    • AASHTO
    • AAR
    • SAE
    • ISO
    • BS
    • DIN
    • DOE
    • MIL

    Examples Include:

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

    Metallurgy/ Testing

    O’Donnell Consulting offers a full spectrum of metallurgical testing to evaluate the root cause of component failure, performing corrosion investigations, surface condition studies, mechanical testing, and weld evaluations.

    Testing includes:

    • Chemical and Mechanical
    • Metallographic Examination
    • Fractography (SEM and TEM)
    • Accelerated Testing of Failure Modes
    • Material Testing
    • Corrosion Testing

    Can’t find what you’re looking for? Try our Search Tool above.

    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 Services. 

     Give us a call to discuss your engineering challenges.

    Failure Analysis Related Links:

    >> Tom O’Donnell, PE
    >> Materials/Metallurgical Consulting
    >> Weld Troubleshooting/ Consulting
    >> Portfolio of Engineering Projects
    >> Introduction to Fatigue 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

    Handbook of Lessons Learned

    (412) 835-5007

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