Failure Analysis Services – Developing Expert Engineering Solutions
Failure Analysis Investigations and Development of Subsequent Engineering Solutions on Damaged / Failed Equipment & Structures to Prevent Recurrence.
Failures can occur during manufacture, shipping and installation, and service. Our team of experts in engineering, metallurgy & welding investigate the root cause of equipment damage / structural failures due to thermal transients, vibrations, thermal fatigue, etc., to ensure structural integrity, and maximize equipment reliability – ultimately controlling costs for owners/ users.
Applications include aluminum, stainless & alloy steels, titanium, and other materials used in industries including Aerospace, Petrochemical, Automotive, Medical, and Energy.
- Pressure Vessels, Piping, Valves, Pumps
- Tanks, Reactors, Dryers, Autoclaves
- Turbomachinery, Shafts, Blades, Gears, Bearings
- Heat Exchangers, Steam Generators, HRSGs
- Machinery, Lift Trucks, Cranes, Welded Structures
For a More Comprehensive List of Equipment, See Applications / Industries Served.
What We Do
Recent Projects
Recent Projects
Root Cause Failure Analysis
- Design Errors
- Material Imperfections
- Manufacturing Issues
- Weld Issues
- Improper Heat Treatments
- Fatigue / Fracture
- Misuse or Abuse
- Improper Maintenance
- Unforeseen Operating Conditions
- Inadequate Quality Assurance
- Environmental Issues (Vibration, Corrosion, etc.)
Failure analysis is a very complicated, systematic process, requiring knowledge and experience in order to reach the proper conclusions. It’s an indispensable tool for manufacturing troubleshooting in all industries, as well as a critical part in forensic legal examinations.
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 design solutions & recommend inspection methods/ intervals 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.
Examples Include:
- Heat Exchangers
- Bellows
- Reactors
- Petrochemical
- Oil/ Gas
- Power Generation
- Refractory
- Ductwork
- Compressors
- Heaters
- Welded Assemblies
Metallurgical Testing
Failure analysis consulting requires metallurgical testing to evaluate the root cause, including corrosion investigations, surface condition studies, mechanical testing, and weld evaluations. This testing includes Chemical, Mechanical, Metallographic and Fractography (SEM & TEM).
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If and when it becomes necessary to present the facts in court, we supply 3-D animations and multimedia presentations to accompany our expert testimony, clearly demonstrating the technical issues for Judges and Juries to easily understand. To read more, see Expert Witness Services.
Call Tom O’Donnell to Discuss Your Engineering Challenges.
Failure Analysis Related Links
>> Tom O’Donnell, PE
>> Materials / Metallurgical Consulting
>> Project: Failure Analysis on Cracked Tube-to-Tubesheet Welds on Chemical Reactor
>> Project: Weld Cracking Investigation on T Bar Section of Cyclone
>> Portfolio: Failure Analysis Projects / Solutions
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
