Failure analysis

A detailed analysis of fracture surfaces is crucial to determine the failure mode of a material (brittle, ductile, fatigue, etc.). Scanning Electron Microscopy (SEM) allows for an in-depth examination of surface topography and the detection of critical defects such as cracks, inclusions, or porosity that contributed to the failure.

Corrosion is one of the leading causes of failure in metallic materials, occurring in various forms such as intergranular corrosion, pitting, or crevice corrosion. Electron microscopy and Energy Dispersive Spectroscopy (EDS) facilitate the examination of corrosion products and help determine the specific cause of deterioration, aiding in future damage prevention.

Hydrogen embrittlement is a phenomenon that compromises the strength of metals, especially steel. SEM analysis helps identify cracks or structural damage caused by hydrogen absorption, improving the understanding of the mechanisms leading to strength and toughness loss.

Surface coatings such as chrome plating, nickel plating, and galvanization are commonly used to protect metals from corrosion and enhance aesthetics. Failure analysis helps diagnose coating issues such as adhesion defects, internal stresses, or premature wear, which may compromise the material’s protection.

Fracture analysis is essential for identifying the root causes of component failure. SEM examination of fracture surfaces provides insight into the fracture mechanism (e.g., fatigue or overload failure) and determines whether the issue stems from design flaws, material defects, or operational conditions.

Defects in manufacturing processes, such as non-metallic inclusions, porosity, residual stresses, or molding defects, can lead to component failure. SEM analysis identifies these defects and assesses their role in material failure, optimizing production processes accordingly.

The presence of organic residues on materials or component surfaces can indicate contamination or material degradation. Techniques such as Fourier Transform Infrared Spectroscopy (FTIR) and Gas Chromatography-Mass Spectrometry (GC-MS) are used to detect chemical traces that may have contributed to failure or material degradation.

Welds are often susceptible to defects that can compromise the strength and reliability of a component. Failure analysis of welds, conducted via SEM, helps identify porosity, cracks, or fusion defects that may cause premature failure of the welded joint.