Failure Analysis Services to Identify Root Cause Metal Defects

Failure analysis investigates why a material, part, or assembly did not perform as intended. The work may include reviewing the failed condition, verifying material conformance, preparing samples, and using destructive or non-destructive testing to collect evidence. The findings can help engineering and quality teams identify contributing factors, validate specifications, and determine appropriate corrective actions or replacement-material requirements.

Failure analysis can include visual examination, document and specification review, destructive testing, non-destructive testing, metallurgical evaluation, and material conformance verification. The appropriate approach depends on the component, service conditions, suspected failure mode, and available sample. A useful investigation often combines multiple methods so the result is based on evidence rather than a single observation.

Request failure analysis when a component fractures, wears unexpectedly, deforms, corrodes, fails inspection, or does not meet its intended performance. It is also valuable when incoming material documentation must be confirmed before production or shipment. Early evaluation preserves evidence and can help prevent repeat issues, avoid unsuitable replacement material, and support informed engineering decisions.

Provide the part’s material specification, certifications or heat documentation, drawings, service history, photographs, operating environment, and a clear description of the failure. Include details such as load, temperature, exposure, installation method, and when the issue occurred when available. This context helps determine suitable testing, sample preparation, and material-verification needs.

Aero-Vac’s in-house saw cutting department processes both its own inventory and customer-supplied material. Independent third-party testing is available to confirm material conformance through destructive and non-destructive methods. Share the material type, dimensions, required specification, and testing objective so the appropriate preparation and testing path can be coordinated.

Destructive testing evaluates a sample by cutting, loading, sectioning, or otherwise altering it to measure characteristics or reveal internal conditions. Non-destructive testing evaluates a part without intentionally damaging it, allowing the component to remain usable when appropriate. Each method has different strengths, and the choice should align with the investigation objective and sample availability.

Timing depends on the sample condition, required test methods, documentation review, and whether custom machining or outside laboratory coordination is needed. Straightforward material verification or sample preparation may move more quickly than a multi-method investigation. Providing complete specifications, photos, and service details at the outset helps reduce delays and supports accurate scheduling.

Yes. Aero-Vac supports material procurement alongside testing and preparation needs. The team can help locate material to the required specification, size, and metallurgical condition, including custom cuts and odd sizes. For volume or turnaround requirements involving thermal processing, Aero-Vac can also coordinate with outside NADCAP heat treaters when needed.