Failure Analysis/Metallurgical Cons

We help clients make informed decisions on product improvements with enhanced reliability and safety.
Our failure analysts have a strong metallurgical background, and our fully equipped laboratory—with state-of-the-art microscopy and metallurgical testing—provides a one-stop solution for evidence collection, testing, and engineering conclusions.

How we work (end-to-end workflow)

1. Define the brief — application, service history, standards, acceptance criteria.
2. Evidence collection — as-received inspection, photography, witness statements, operating data.
3. Non-destructive screening — visual, dimensional, NDT (UT/RT/MT/PT as applicable).
4. Fractography & microscopy — macro/micro examination of fracture features, crack origin, propagation mode.
5. Metallography — microstructure, grain size, inclusions, case/decarb, weld/HAZ condition, delta-ferrite/sensitization (as relevant).
6. Chemistry & materials checks — PMI/OES, wet chemistry, contaminants/coating checks.
7. Mechanical evidence — hardness/microhardness profiles, tensile/impact where representative; replication if needed.
8. Corrosion assessment — IGA/IGC, pitting/crevice, environment review; salt/humidity tests where applicable.
9. Stress/fitment review — loads, misalignment, residual stress, assembly tolerances; compare to design/code.
10. Root-cause conclusion (RCA) — tie evidence to mechanisms (overload, fatigue, SCC, wear/erosion, hydrogen damage, embrittlement, improper heat treatment, material non-conformance, etc.).
11. Corrective & preventive actions (CAPA) — material/process changes, design tweaks, inspection intervals, environment control, coatings, workmanship/training.