Full definition
The systematic investigation of a component or system that has failed prematurely (before reaching expected service life), using engineering tools and methodologies to identify the failure mode, mechanism, and root cause. The analysis provides the evidence base for corrective actions that prevent recurrence. Key steps: (1) Preserve and document — photograph in-situ, collect all fragments, record operating history and maintenance records. (2) Visual examination — fracture surface features (beach marks = fatigue, dimpled rupture = ductile overload, cleavage = brittle fracture, intergranular = corrosion/creep). (3) Non-destructive testing — dye penetrant, magnetic particle, ultrasonic, or X-ray to reveal subsurface defects. (4) Destructive testing — metallography (cross-section microstructure), hardness testing, chemical analysis (verify material grade), SEM/EDS (fracture surface morphology and elemental analysis). (5) Mechanical testing — tensile, impact, fatigue on similar material samples. (6) Root cause determination — correlate findings with operating conditions. Per ASTM E2332 (failure analysis methodology), ASM International Failure Analysis and Prevention, and API 579 (fitness-for-service). For rubber products: analyze failure patterns (flex cracking, ozone cracking, chemical attack, heat degradation, mechanical damage), test samples (hardness, tensile, compression set, FTIR for compound identification).