Failure Analysis Services | Element Materials Technology

Failure analysis is a critical aspect of product development and system improvement. Element’s team of scientists and engineers have decades of hands-on experience performing root cause analysis for failures across many sectors, including aerospace, oil & gas, transportation, medical device, construction, consumer products, and more.

Failure analysis is a multi-faceted, holistic approach to product and material investigations. The failure analysis process begins with the determination of how and why the sample failed. This initial stage involves an in-depth discovery phase in which one of Element’s expert failure analysts collects information on the circumstances surrounding the failure and any relevant background information, including environmental factors, type of application, service life, pertinent design information and, ultimately, method of the failure. Element's failure analysts then apply analytical tools to inspect the failed part, often comparing it to other, similar parts that are still intact.

While identifying root cause is usually the primary goal in failure analysis, the real value of a failure analysis is to identify what can be done to prevent future occurrences. Based on findings from this process, Element experts provide recommendations and team with the customer to find solutions to problems for a diverse range of products and materials. It is the combination of our expertise in materials selection and application, manufacturing processes, fracture mechanics and the impact the actual service environment can have on a material or product that enables Element to rapidly deliver comprehensive recommendations to avoid service failures and resolutions to future manufacturing challenges.

Failure Analysis

Common Failure Modes Analyzed

Corrosion
Creep
Design Defects
Environmental (Temperature & Humidity) Exposure
Errant Heat Treatment
Fatigue
Fracture
Hydrogen Embrittlement
Mechanical Overload
Stress Corrosion Cracking
Wear

Failure Analysis

Common Failure Analysis Techniques

Accelerated Aging
Corrosion Testing
Differential Scanning Calorimetry (DSC)
Fatigue Testing
Fourier Transform Infrared Spectroscopy (FTIR)
Fractography
Gas Chromatography–Mass Spectrometry (GC-MS)
Impact Testing
Investigative Chemistry
Macroscopic Evaluation
Material Compatibility Testing
Mechanical Properties Testing
Microscopic Evaluation
Residue/Contaminant Analysis
Scanning Electron Microscopy with Energy Dispersive X-Ray Spectroscopy (SEM-EDS)
Thermogravimetric Analysis (TGA)
Thermomechanical Analysis (TMA)
X-Ray Powder Diffraction (XRD)

Failure Analysis

Materials We Analyze

Element failure analysis experts are well-versed in determining root cause of failure for a wide range of materials, including metals and alloys, plastics and polymers, advanced composites, rubber, adhesives, sealants, paints, and coatings.

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Metals Failure Analysis

Element’s metal testing laboratories provide comprehensive failure analysis services for forgings, castings, and various other metallic components, which are often subjected to harsh working environments under high stress applications.

From corrosion and fatigue to errant heat treatment and hydrogen embrittlement, our metals experts have the tools and expertise necessary to identify and diagnose field failures in a timely manner.

Typical Metallic Materials Tested:

Aluminum
Cast Iron
Chrome
Cobalt
Copper
Inconel
Magnesium
Molybdenum
Nickel
Powder metal
Steel
Titanium
Welds

Non-Metals Failure Analysis

Due to the countless material formulations and combinations, Element's polymer and nonmetal failure analysis laboratories often employ intensive material identification programs to assist in determining the origin of failure.

Unlike metals, a polymer’s identification typically cannot be identified from any single technique. Often, chemical analyses are combined with thermal properties testing to form a clear picture of the material’s identity and origin.

Common Non-Metallic Materials Analyzed:

Acrylics
Carbon Fiber and Carbon Fiber Reinforced Plastic (CFRP)
Ceramic Matrix Composites (CMCs)
Fiberglass
Polybutylene
Polyethylene
Polymer Matrix Composites (PMCs)
Polymers & Plastics
Polypropylene
Polytetrafluoroethylene (PTFE)
Polyvinyl chloride (PVC)
Rubbers & Elastomers
Silicon Carbide

Failure Analysis

Industries We Serve

Element’s highly-trained staff of material experts have extensive knowledge and expertise across a wide range of industries, from aerospace and transportation to consumer products and construction.

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Aerospace Failure Analysis

Element’s aerospace testing laboratories provide indispensable failure analysis services to Aerospace primes and their supply chain partners. As the largest independent testing company in the global Aerospace sector, we're in the best position to provide you with expert failure analysis services and timely solutions to your toughest material or component challenges.

Common Aerospace Components Analyzed:

Airfoils
Ball Bearings
Bushings
Components and Subcomponents
Fan Blades
Fasteners
Fittings
Gears
Instruments
Turbines

Oil & Gas Failure Analysis

Reservoir souring, extreme pressures and temperatures, fatigue regimes, and inaccessibility for maintenance count among the myriad of technical challenges faced by the Oil & Gas industry. Tight oil, ultra-deep water, oil tar sands, arctic conditions and conventional extraction are just some of the challenges being met by Element’s ever-more responsive and inventive failure analysis services.

Common Oil & Gas Components Analyzed:

Ball Bearings
Bushings
Downhole/Downstream Components
Drilling Rig Components
Fasteners
Fittings
Flanges
Gears
Hoses
Instruments
Lines
Motors
Pipeline
Pumps

Transportation Failure Analysis

Working with OEMs and their suppliers from late R&D, through design validation and on to production validation, Element’s main mission is to provide you certainty. So whether you are designing systems and components for light-, medium- or heavy-duty vehicles, our engaged industry experts will work together with you to solve your toughest material and product challenges.

Common Transportation Components Analyzed:
Chassis & Suspension
Electronics & Battery
Fuel Components
HVAC, Fluid, and Cooling Systems
Interiors & Exteriors
Lighting & Glass
Plant equipment components, including shafts, press housings, springs, pulleys, chains, cables, bearings, hooks, etc.
Powertrain
Safety Systems

Industrial Failure Analysis

Industrial manufacturing processes create harsh working environments for materials and components. In addition, failures on the manufacturing line create catastrophic delays in production. Element’s failure analysis experts have the resources and knowledge to provide timely on-site or in-lab investigations for a myriad of industrial manufacturing failures.

Common Industrial Components Analyzed:

Ball Bearings
Bushings
Tools and Dies
Electronic components and sensors
Fasteners
Fittings
Pipes, Fittings and Flanges
Gears
Hoses
Tanks and Pressure Vessels
Instruments
Lines
Plant equipment components, including shafts, press housings, springs, pulleys, chains, cables, bearings, hooks, etc.
Presses
Pumps and Impellors

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Our capabilities

Materials Testing Services

4 MeV Radiographic Inspection Abrasion and Wear Testing Aerospace Fasteners Aircraft Interiors Flammability Testing Chemical Analysis Chemical Processing Composite Testing Contaminant Testing Corrosion Testing Die Steel Qualification Differential Scanning Calorimetry (DSC) Dynamic Mechanical Analysis Eddy Current Inspection Etching Expert Witness Services Failure Analysis Fastener Testing Fatigue Testing FEA

Foam Testing FTIR Fractography Services Fracture Toughness Hardness Testing Hydrostatic Testing Impact Investigative Chemistry Liquid Penetrant Inspection Magnetic Particle Material Properties Mechanical Testing Metallography and Micro Examination Metallurgical Testing NDT Field Services Nondestructive Testing and Inspection Nonmetals Failure Analysis Nonmetal Mechanical Testing Nonmetal Testing

On-site metallographic examination Paints and Coatings Analysis Passivation Polymer Matrix Composite Testing Polymer Testing Services Positive Material Identification Radiographic Inspection Residual Stress Measurement Residue Analysis Sour Service Corrosion Testing Stress Rupture and Creep Testing Stress Strain Analysis Tensile Testing Thermogravimetric Analysis (TGA) Thermomechanical Analysis (TMA) Ultrasonic Testing Ultraviolet Exposure Visual Inspection Weld Testing and Weld Failure Analysis

Making Certain for nearly 190 years

Service

Fractography Services

Our fractography services can help determine the cause of failure, fatigue, or defects in metallic materials.

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Polymer Testing

Our experts deliver world-class materials expertise in polymeric materials including elastomers, thermoplastics, composites and structural adhesive related testing services.

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