Failure Analysis Services
Investigate why a material, component or product failed. Anysis combines failure history, microscopy, materials characterization and targeted analytical testing to identify evidence consistent with likely failure mechanisms.
What Is Failure Analysis?
Failure analysis is a systematic investigation used to understand why a material, component or product did not perform as expected. The objective is to move from the visible symptom—such as a fracture, corrosion, delamination, discoloration or loss of performance—to evidence about the underlying failure mechanism and contributing factors.
A strong investigation starts before laboratory testing. Service history, operating conditions, manufacturing changes, photographs, fracture location and comparison samples can be as important as the instrument data.
Questions This Service Can Help Answer
- Where did the failure initiate, and what does the damage pattern reveal?
- Is the issue related to material selection, processing, contamination or service conditions?
- How does the failed sample differ from a known-good component or earlier batch?
- What additional evidence is needed to distinguish between competing root-cause hypotheses?
Failure Modes We Can Help Investigate
The exact workflow depends on the failed material and the evidence available. Investigations may focus on one failure mode or several interacting mechanisms.
Cracking & Fracture
Examine fracture features, initiation zones, microstructure and material condition.
- Brittle/ductile features
- Crack origin
- Material defects
Corrosion & Chemical Attack
Investigate corrosion products, local chemistry and environmental contribution.
- Pitting/deposits
- Surface chemistry
- Material/environment interaction
Wear & Surface Damage
Study abrasion, erosion, transfer, roughness and localized surface changes.
- Wear morphology
- Debris identification
- Surface condition
Adhesion & Delamination
Examine coating, adhesive or interface failures and possible contamination.
- Interface chemistry
- Coating defects
- Bond-line evidence
Residues & Foreign Material
Identify particles, residues or unexpected materials associated with the failure area.
- Particles
- Process residues
- Unexpected substances
Aging & Material Degradation
Investigate thermal, chemical or environmental changes that may reduce performance.
- Oxidation
- Polymer degradation
- Thermal history
Typical Failure Analysis Techniques
Methods are selected to answer specific hypotheses. The goal is not to run every available instrument, but to use the minimum set of complementary methods that can distinguish likely failure mechanisms.
Method selection is project-specific. Final technique, sample preparation and reporting scope should be confirmed before testing begins.
Optical Microscopy
Initial visual and fracture examination
SEM-EDS
High-resolution morphology + elemental analysis
FIB / Cross-Section
Localized cross-sectional investigation
FTIR / Raman
Organic residues and polymer changes
XPS / TOF-SIMS
Surface chemistry and contamination
XRD
Crystalline phases and corrosion products
DSC / TGA
Thermal history and degradation
Mechanical Testing
Property comparison and verification
ICP-MS / ICP-OES
Elemental composition and impurities
GC-MS / LC-MS
Organic contaminants or degradation products
Hardness / Nanoindentation
Localized mechanical properties
Profilometry / AFM
Surface topography and roughness
When to Start a Failure Analysis
The analytical scope should be tied to a real technical or business decision—not simply to a list of available instruments.
Field Returns
Investigate components that fail earlier than expected during service.
Manufacturing Problems
Understand defects that appear after a process, material or equipment change.
Supplier Quality
Compare failed parts with supplier references or incoming material specifications.
Recurring Defects
Identify evidence that explains repeated cracks, residues, discoloration or delamination.
Product Improvement
Use failure evidence to guide material, design or process improvements.
Good vs. Bad Comparison
Apply the same analytical plan to failed and functioning samples to isolate meaningful differences.
What You May Receive
Deliverables are structured to help identify failure mechanisms and support root-cause decisions. Findings may combine visual evidence, analytical data, comparisons and technical interpretation.
Failure Evidence
Microscopy, photographs and analytical observations documenting the location, morphology and characteristics of the failure.
Root Cause Findings
Evidence-based assessment of the mechanisms and contributing factors most consistent with the observed failure.
Supporting Analytical Data
Relevant spectra, images, elemental data, measurements or comparative results supporting the investigation.
Recommended Next Steps
Technical interpretation and suggested verification, process review or additional analysis where further investigation is appropriate.
From Your Question to Useful Results
The process begins with the decision you need to make, then defines the analytical scope, sample plan and deliverables.
Preserve & Document
Record failure condition, service history and sample orientation before destructive preparation.
Examine & Form Hypotheses
Use visual/microscopic evidence to identify likely initiation sites and possible mechanisms.
Test the Hypotheses
Apply targeted chemical, structural, thermal, surface or mechanical analysis.
Integrate the Evidence
Summarize findings, confidence level and the evidence supporting the likely failure mechanism.
Failure Analysis FAQs
Clear answers about method selection, samples, project scope and analytical expectations.
Have a Failed Component?
Send photos, service history and the sample condition before cleaning or cutting. We can help plan the investigation.
What information is most useful before a failure analysis?
Provide service history, time to failure, photographs, drawings, operating conditions, recent process or supplier changes and any known-good comparison samples.
Should I clean the failed part before sending it?
Usually no. Cleaning can remove residues, corrosion products or particles that are important evidence. Ask the laboratory before altering the sample.
Can you determine the exact root cause of every failure?
Usually no. Cleaning can remove residues, corrosion products or particles that are important evidence. Ask the laboratory before altering the sample.
Can you compare failed and good samples?
Yes. Good/bad comparison is often one of the most effective ways to isolate meaningful material, surface or composition differences.
Which techniques are used for failure analysis?
The investigation may use microscopy, SEM-EDS, FTIR/Raman, XPS, XRD, thermal analysis, elemental analysis, mechanical testing and other targeted methods as appropriate.
Can you analyze residues or particles found at the failure site?
Yes. Localized residues and particles can be critical evidence and may be investigated using material identification, surface analysis or impurity-analysis methods.
How much sample is needed?
The failed component should be preserved as completely as practical. Additional reference, unused or known-good samples can substantially improve the investigation.
How long does failure analysis take?
Lead time depends on complexity and whether the project proceeds in stages. Initial observations may guide additional analytical work before a final report is completed.
