Performing failure analysis – resolving materials, weld, vibration, fatigue and other operational issues to prevent recurrence. Ensuring structural integrity, and maximizing equipment reliability & controlling costs for owners/ users.
Our Team of Engineers has investigated the root cause of failures due to thermal/ transients, vibrations, thermal fatigue, weld failures and more.
Applications include aluminum, stainless steels, titanium, nickel based and exotic alloys used in aircraft, ships, petrochemical plants, industrial machinery, automotive components, tanks, food processing equipment, ASME boilers and pressure vessels, process equipment, medical supplies and oil/gas pipelines.
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
- 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. 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 potential component failure modes, we recommend inspection methods/ intervals, and design solutions to reduce the likelihood of future failures – ensuring structural integrity.
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.
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
- Heat Exchangers
- Oil/ Gas
- Power Generation
- Welded Assemblies
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.
- Chemical and Mechanical
- Metallographic Examination
- Fractography (SEM and TEM)
- Accelerated Testing of Failure Modes
- Material Testing
- Corrosion Testing
Our failure analysis experience covers a broad range of industries, materials, and equipment. For a comprehensive list, see Industries Served.
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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
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