ROOT CAUSE FAILURE ANALYSIS

Corrosion Resolutions personnel have performed well over 100 root cause failure analyses.  The analytical method we use begins with an in-depth review of materials and available historical and other records/information.  Thereafter, a series of analytical tests are selected and performed, the results of which invariably identifies the failure mechanism(s) and its (their) root cause(s).  All analytical data is reduced and then analyzed in a highly detailed, logical process of elimination manner.

 Tests involved in a typical failure analysis would include:  1)  nondestructive examination to locate and characterize the failure site(s); 2)  stereomicroscopic examination to further characterize the failure type(s) by morphology and to select specifically characteristic test areas for subsequent spectroscopic analysis;  3)  metallurgical chemistry analysis to verify that the failed component alloy chemical composition is as specified;  4)  metallography to characterize the nature of the defect(s) and to evaluate potential adverse microstructural conditions, if any, that may have contributed to the failure cause(s); and 5)   scanning electron microscopy – energy dispersive spectroscopy (SEM-EDS) to spectroscopically identify the corrodent(s) and its (their) concentration(s) deep within defect sites.

If required, one or more other analytical tests may be performed.   The most probable additional tests that would be considered are:

·         Inductively coupled plasma spectroscopy (ICP) for determination of the gross scale chemistry

·     Fourier transform infrared spectroscopy (FTIR) to evaluate the potential of specific organic materials being involved in the failure(s)

·         Scanning Auger microanalysis (SAM) for chemical characterization of ultra-thin films

·         Electron spectroscopy for chemical analysis (ESCA) or X-ray diffraction (XRD) to identify the molecular, versus the elemental, nature of corrosion products and/or corrodents

·         X-ray mapping to define the nature and distribution of corrodents with respect to the analyzed failed site(s) and adjacent areas where corrosion did not occur

·         Various sophisticated microbiological tests of the coolant and/or corrosion product(s) to determine if microbiologically influenced corrosion (MIC) is involved in the  failure

Note that additional testing was not required for the performance of over 90% of the root cause failure analyses that Corrosion Resolutions has previously conducted.

The end product is a laboratory results documented root cause failure analysis report that contains citations of analytical findings, a detailed discussion, conclusions, and definitive corrective action recommendations.

For Example Diagnostic Photographs click here

For a  Methodological Example of a Failure Analysis click here

For a listing of Selected Engineering Myths that Perpetuate Corrosion Failures click here

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For additional information please send email to:  CorrRes@aol.com