When a component fails in the field, the pressure to identify the cause quickly is real. Production may be on hold. A customer is waiting. The temptation is to guess. Failure analysis exists to replace the guess with data, and understanding the process helps you get useful results faster.
Step 1: Visual and stereomicroscope examination ¶
The first stage is low-magnification examination of the failed component in the condition it arrived. We document the fracture surface, any deformation, surface condition, and the location of the failure relative to the component geometry. This stage often reveals more than clients expect. Fatigue failures, for instance, frequently show beach marks visible at 10x magnification that already indicate the crack initiation site and propagation direction.
Step 2: SEM fractography ¶
The fracture surface is examined under a scanning electron microscope at magnifications from 50x to 5,000x depending on the feature of interest. Fractographic features. Striations, dimples, cleavage facets, intergranular separation. Indicate the failure mode. A ductile overload failure looks very different from a fatigue failure or a stress corrosion crack. This distinction drives the rest of the investigation.
Step 3: EDX elemental analysis ¶
Energy-dispersive X-ray spectroscopy at selected locations on the fracture surface and the surrounding material confirms composition and can identify contamination or unexpected phases. Corrosion products, inclusions, and surface coatings all produce characteristic spectra. If the material composition does not match the specified alloy grade, that is noted in the report.
Step 4: Root cause statement and corrective actions ¶
The final report section states the most probable cause of failure based on the evidence collected, with a confidence level where appropriate. It also includes two to four corrective action recommendations. These are specific to the failure mechanism identified, not generic quality advice. A fatigue failure at a stress concentration gets different recommendations than a hydrogen embrittlement case.
Turnaround and report format ¶
Standard failure analysis cases are completed within 10 working days of sample receipt. Rush processing (5 working days) is available at a surcharge. Reports are issued in English with a Japanese version available at no extra charge. The Failure Analysis Starter package covers visual examination, SEM fractography, and EDX at three locations, starting from ¥65,000.
If you have a component failure and are not sure whether it warrants a full investigation, contact us at lab@driftcorelab.com with a photo and a brief description. We will give you an honest assessment of whether testing is likely to be useful.