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Principles of Failure Analysis

ASM HOMESTUDY COURSE (7-Lesson Series)

Course Overview:

• Profit from failure analysis techniques
• Understand general failure analysis procedures
• Learn fundamental sources of failures

This course is designed to bridge the gap between theory and practice of failure analysis.

This course presents a very practical approach to failure analysis for the non-metallurgist as well as for those who are new to the field or those who want an update. It is also designed for technicians and those interested in understanding how knowledge of failure analysis can lead to better productivity.

A comprehensive overview of the field, this course covers three principal areas of interest: Procedures for Analysis, Failure Mechanisms and Failure in Product Forms and Components. Causes of failures are explained with easy-to-understand diagrams of stress application and distribution. Many case histories of failures and their elimination are highlighted throughout the course.

What You'll Learn:

• Learn what failure analysis can mean in terms of profitability - and liability
• Understand general procedures, techniques and precautions in failure analysis
• Learn how to identify design-related failures
• Be able to analyze the factors that cause failure
• Understand what environmental sources are responsible for failures and ways to prevent them
• Learn how stress systems relate to fracture of ductile and brittle materials
• Learn about typical fatigue characteristics
• Grasp the many inter-related factors involved in examining a fracture
• Understand the basic fracture modes and their characteristics, including the factors affecting ductile-brittle relationships
• Become knowledgeable about typical fatigue characteristics and learn how to identify them
• Learn how to "read" fatigue fractures
• Learn how to separate material (chemistry, microstructure) causes for failure from non-materials causes

Course Outline:

1. General Procedures for Failure Analysis: collection of data and samples;
preliminary examination; non-destructive inspection; mechanical testing; selection
and preservation of fracture surfaces; macroscopic and microscopic examination;
selection; preparation and examination of metallographic sections; fracture classification;
report writing

2. Types of Failure and Stress: fracture, wear, corrosion, and distortion failures; tensile, compressive, torsional and shear stresses; residual stress

3. Ductile and Brittle Fractures: definitions and comparisons; dimple rupture; tearing and shearing; plastic deformation ductile-brittle transition; cleavage; intergranular fracture; thermally-induced and environmentally-assisted embrittlement; effect of fabrication and heat treatment; residual stress

4. Fatigue Failures: factors affecting fatigue life; stages of fatigue fracture; fatigue cracking; effects of variables; mean stress; stress concentration; metal characteristics; manufacturing process; elevated temperatures; contact fatigue

5. Wear Failures: abrasive wear; adhesive wear; role of friction; lubricated wear; lubricant failures; nonlubricated wear; examination of worn parts; effect of microstructure and hardness; surface-fatigue pitting; wear rates

6. Corrosion Failures: electro-chemical reactions; types of corrosion; velocity-affected corrosion; bacterial and bio-fouling underground corrosion; atmospheric corrosion; corrective and preventative measures; stress corrosion cracking; analysis of failure

7. Elevated-Temperature Failures: creep; stress rupture; thermal fatigue; effect of atmospheric environment; failures in industrial application; testing techniques

Who Should Enrol:

This course is primarily intended for people who are new to failure analysis or for those who want an update. It is also designed for technicians and those interested in understanding how knowledge of failure analysis can lead go better productivity.

Continuing Education Units: 3.0

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The Institute of Materials Engineering Australasia Ltd, trading as Materials Australia, is also a technical society of Engineers Australia, Suite 205 / 21 Bedford Street, NORTH MELBOURNE VICTORIA AUSTRALIA 3051
Tel 61 3 9326 7266 Fax 61 3 9326 7272
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