Failure Analysis

The approach to failure analysis at Dayton T. Brown, Inc. is unique and unparalleled by other engineering houses, especially during the critical early evaluation stage.

DTB can bring to bear a broad range of failure analysis expertise that can be pulled into the process quickly and efficiently.

A quick failure analysis consultation with an electrical, test, or structural engineer can provide key insights into a components’ failure modes and on how to improve the design or manufacturing process.

Please refer to the Library of Failure Analyses on this site to see examples of how a focused failure analysis can lead to product design improvements.

The following steps of a product failure analysis are based on a metallurgical failure analysis procedure, but have been adapted to provide key insights into other types of components as shown in the library of failure analysis reports.

DTB’s 8-Step Failure Analysis Process for Metallurgical Issues

Note: For “Non-Metallurgical Failures”, other engineering disciplines would be integrated.

1.) Background

It is vital to obtain as much background information as possible about a failed item and its design and intended use.

2.) Failure History

Information specific to the actual environment is also vital to the failure analysis, especially when compared to the nominal design requirements and configurations.

3.) External and Non-destructive evaluation

Overall examination of the component is performed in the "as received" condition through the use of high resolution digital imaging, liquid penetrant or magnetic particle flaw detection, x-ray imaging, and other non-destructive failure analysis methods.

4.) Fractographic Analysis

Examination on a more detailed basis of the fracture surfaces using failure analysis tools such as stereomicroscopy, scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS).

5.) Metallographic Analysis

For failure analysis of metallic components there is no substitute for experience and our metallurgical staff has examined literally thousands of failure surfaces. They will quickly focus in the salient aspects of the failure analysis problem by examining the following:

6.) Failure Cascade Determination

By utilizing insights from the entire DTB engineering staff and detailed observations from the failure analysis a cascade of events leading to the failure can often be determined.

7.) Isolation of Root Causes

Using insight gained from the failure analysis of the failed component, as well as fundamental engineering insights from decades of experience, the root cause of the failure is determined and recommendations for Failure Prevention are formulated.

8.) Recommendations for Failure Prevention

After completing the failure analysis, our Design Engineering staff can provide various viable product improvement measures based on input from you on costs, complexity and reliability requirements. In our testing business we see product failures every week, thus we have developed an inherent expertise in making corrective design recommendations for many different products in many different markets.