Failure Analysis Lab - Materials Testing

Failure Analysis of Materials

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In our failure analysis lab, we investigate a material failure’s background or history of a sample, to determine why a particular failure occurred. A product failure may include premature breakage, discoloration or even an unexpected odor. It is useful to know if this failure is a new, unique occurrence or if it has been an ongoing issue. The investigation can involve analyzing the sample as it currently exists and extrapolating from that data what may have caused the failure. A sample of the “good” vs. “bad” product may also be useful for comparison purposes.

Physical failures (e.g. poor adhesion, pull strength, fractures, discolorations) are investigated using surface analysis, materials characterization and metallurgical analysis techniques. The scenario and sample type impact which analytical technique can be used.

EAG has a variety of instrumentation in our failure analysis labs, such as Optical Microscopy, SEM/EDS, FTIR, Raman, TOF-SIMS, XPS, and Auger. We also work with experts in metallurgical failure analysis and fracture analysis to better understand the mechanics of the fracture, failure modes and origins .

Environmental chambers are available for failure analysis, to test the effects of UV, heat and humidity on materials and products. Additionally, to better understand the problem, failure conditions can be re-created in the laboratory. Both customized analyses and application of established standards such as ASTM methods may also be employed.

For adhesion and bonding failures, FTIR, TOF-SIMS, XPS and Auger are important techniques that provide information about the molecular and/or elemental species present at the failure site. In some instances, the presence of molecular contaminants at delaminated surfaces can indicate poor contact between the bonded surfaces. Imaging delaminated surfaces can also indicate the failure mechanism (e.g. cohesive or adhesive).

Failure Analysis Examples

EAG has successfully determined the cause of failure due to:

Fatigue and other slow crack growth mechanisms
Brittle and ductile overload failures
Stress corrosion and hydrogen embrittlement failures
Corrosion/oxidation problems
Contamination problems
Wear failures
Adhesion and bonding problems
Discoloration
Heat treatment problems
Design/stress related failures
Plating problems

Related Resources

Other failure analysis scenarios may involve analyzing unknown materials or investigating the unexpected appearance of a surface, due to particles, roughening or discoloration. EAG failure analysis lab scientists have investigated:

Plastics
Adhesives
Packaging
Metals/alloys
Coatings/paints
Composites
Laminates

Failure analysis & materials testing of metal components, plastics or composite materials has applications across a variety of industries, including aircraft, aerospace, transportation, construction, consumer products, electronics, hostile service environments, energy production, structural components and medical devices. Materials selection based on your engineering specifications is one of EAG’s many specialties. The potential complexity of a failure analysis investigation means that EAG’s expertise in experimental design, instrument operation and data interpretation all increase the likely chances of success.