Failure Analysis Services
Determine root cause(s) of failure in components, devices, structures, and systems
Regardless of industry, design, material selections, manufacturing and service conditions, failures can often result due to factors, either singly or in combination.
Failure Analysis (FA) services are often required in the design, process, quality assurance and inspection functions of products, plants, equipment, and facilities, because it can analyze and determine root causes of failures that involve material defects, manufacturing defects, design flaws, overstress ( overloading ) or environmental causes.
In addition, our services are also sought after during forensic investigations of commercial or industrial failure incidents for validating insurance claims, compensation lawsuits or to apportion liabilities and responsibilities between relevant stakeholders.
TÜV SÜD Failure Analysis team possesses state-of-the-art tools, and techniques that can help our customers prevent future failures or incidents from recurring, and our services can be further categorized into 3 levels.
Level 1 - Visual examination and some non-destructive analysis, with only expert opinion regarding possible causes provided in the FA report
Level 2 - Visual examination, non-destructive and limited destructive analysis. FA report will provide mechanisms and cause(s) of the failure, as well as suggestions for corrective or preventive measures
Level 3 -Comprehensive investigation scope, including any necessary analysis methods to conduct an investigation. FA report will include detailed mechanisms and root cause(s) of the failure or incident; recommendations on counter measures will be also provided. At this level, TÜV SÜD will offer our full support in any technical negotiation or legal litigation with parties who are relevant to the case.
Your benefits at a glance
- Identify the root cause of faults and receive solution proposals from our experts.
- Our unique testing approach blends automated and manual tools to identify thousands of possible issues.
- Proven reliability and technical competency for customers over a long period.
- Dedicated customer service and technical teams to address queries and specific requirements of customers.
We are able to handle:
- Metallic Materials (Steels, S.S., Cast Iron, Al-Alloys, Cu-Alloys, Ni-Alloys, Ti-Alloys, Powder-Metallurgy Alloys, etc.)
- Polymeric Materials (PVC. PE, PET, ABS, PP, PC, PA, EPDM, etc.)
- Ceramic Materials (WC, TiN, SiC, BaTiO3, Al2O3, etc.)
- Composite Materials (FRP, PRM, M/P/C laminates, etc.)
- Thin-Film Materials
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Aerospace Industry
- We have successfully completed more than a hundred failure analysis projects for the aerospace industry including investigations on failed HPT blades, HPC blades, vanes, fan blades, rotor disk, stator, rotor bearing, starter shaft, oil duct, main landing-gear & nose landing-gear components, balance rudder, exhaust nozzle, engine mount, crashed helicopter, elevator of helicopter, etc.
Material and process evaluations to prevent special failure mechanisms such as hydrogen embrittlement (HE), hydrogen-induced cracking (HIC), stress corrosion cracking (SCC) and corrosion fatigue (CF), creep damage, etc.
Amusement Industry
- Our failure analysis projects for the amusement industry includes investigations on cracked roller coaster rail, shafts of vehicles, welded steel structure of vehicles, brakes, etc.
- Material and process evaluations to prevent improper design and manufacturing process which may result in special forms of damages such as hot cracking, fatigue cracking, pitting, intergranular attack, brittle cracking, etc.
Automotive Industry
- TÜV SÜD FA services can help in the investigation of failures involving horns, head lightings, steering wheels, tires, exploded air-compressors, PCBAs of automobiles, etc.
Material and process evaluations to prevent special forms of damage such as galvanic corrosion, pitting corrosion, intergranular attack, stress corrosion cracking (SCC), hydrogen embrittlement (HE), arcing, etc.
Chemical Industry
- TÜV SÜD’s FA services for chemical (including oil refinery & petrochemical) industry includes investigations on various failed devices such as high-T & high-P reactors, heat-exchangers, boilers, economizers, pumps, tanks, valves & piping, hydrogen furnaces, composite tanks and piping for concentrated acids /caustics, etc.
Material and process evaluations to prevent special forms of corrosion such as pitting corrosion, intergranular attack, stress corrosion cracking (SCC), corrosion fatigue (CF), firing, explosion, etc.
Construction & Infrastructure Industry
- TÜV SÜD’s FA services for construction and infrastructure industry including investigation on failed lifting equipment, steel wire ropes, welded steel structures, aero-platform, scaffolds, tower cranes, caterpillar cranes, piling machines, man-lifts, copper pipes & fittings, cast iron pipes & fittings, window frames, window glass, tempered glass panels,metallic decorations, marble/granite/ceramic tiles, paintings, etc.
Material and process evaluations to prevent special forms of damage such as pitting corrosion, intergranular attack, discoloration, stress corrosion cracking (SCC), aging, thermal shock, etc.
Consumer Products Industry
- We have completed more than hundred failure analysis projects for consumer products industry including investigations on failed computers, printers, switches, cables, electric fans, batteries, bicycles, fasteners, TV set components, hand phone components, furniture, various metal products and semi-products, etc.
Material and process evaluations to prevent special forms of damage such as pitting corrosion, intergranular attack, discoloration, stress corrosion cracking (SCC), aging, circuit open, short cut, arcing, fire incident, etc.
Food Industry
- TÜV SÜD’s FA services for food industry includes investigations on contamination/foreign objects in milk powder, contamination/foreign objects in quick meal products, food cans, aluminum foils for food package, polymeric pail/spoon for food products, etc.
Material and process evaluations to prevent special forms of damage such as contamination, pitting corrosion, intergranular attack, filiform corrosion, improper management etc.
Healthcare Industry
- TÜV SÜD’s FA services for healthcare industry includes investigations on failed medical devices for heart operation (e.g. guide-wires, venous return cannula, etc.), stainless steel needles, different polymeric cannula, fitting luer, pressure tubing, PA catheter, uniject, laryngeal mask, clamshell of laryngeal mask, surgical-implant parts, surgical equipment, pharmaceutical devices, etc.
Material and process evaluations to prevent special forms of damage such as contamination, pitting corrosion, intergranular attack, discoloration, stress corrosion cracking (SCC), poor workmanship, aging, etc.
Electronics Industry
- TÜV SÜD’s FA services for electronics industry including investigations on various IC chips, PCBs, PCBAs, multiple-layer capacitors, resistors, computers, hand phone sets, electrical cables, insulators, antennas, satellite ground station equipment, etc.
Material and process evaluations to prevent special forms of damage such as galvanic corrosion, pitting corrosion, intergranular attack, stress corrosion cracking (SCC), hydrogen embrittlement (HE), arcing, insufficient etching-back, etc.
Marine Industry
- We have completed more than hundred failure analysis projects for marine industry including investigation on failed ship main engines, generators, turbochargers, gearboxes, propeller shafts, propeller bearings, crankshaft, engine bearings, con-rod & piston & cylinder liner system, cylinder headers, engine block, submarine engines, submarine battery, piping & valves, hovercraft engine, ship-lifting systems, port cranes, off-shore rigs, sub-marine power cables, oil-tanker structures, ship hull structures, winch, underwater painting, diving equipment, etc.
- Material evaluations to prevent special form of corrosion including pitting corrosion, intergranular attack, stress corrosion cracking (SCC), corrosion fatigue (CF), bio-fouling, excessive CP, fire and/or explosion incident, etc.
Power & Energy Industry
- TÜV SÜD’s FA services for power & energy industry including investigations on failed boilers, gas turbine components, steam turbine components, combustion chambers, generator rotor shaft, air pre-heater, economizers, different power cables, fuel pumps, electric distribution equipment, transformer, switch gears, control panels, oil & gas exploration equipment (drilling machine), gas piping, wind turbine bearings, oil tanker structures, floating hoses, UPS system, etc.
Material and process evaluations to prevent special forms of damage such as high-T oxidation, High-T sulfidation, hot corrosion, pitting corrosion, intergranular attack, corrosion fatigue (CF), stress corrosion cracking (SCC), fire and/or explosion incident, etc.
Rail Industry
- TÜV SÜD’s FA services for rail (including land transport) industry including investigations on cracked rail, corroded rail, failed train gearbox, accident of train overhead collection system (OCS), accident of third rail system, surge arresters, corroded MRT station structures, tunnel equipment & structures, etc.
- Material evaluations to prevent special forms of damage such as rolling-contact fatigue, pitting corrosion, intergranular attack, stray-current corrosion, stress corrosion cracking (SCC), corrosion fatigue (CF), flashover, fire incident, etc.
We are able to handle:
- Metallic Materials (Steels, S.S., Cast Iron, Al-Alloys, Cu-Alloys, Ni-Alloys, Ti-Alloys, Powder-Metallurgy Alloys, etc.)
- Polymeric Materials (PVC. PE, PET, ABS, PP, PC, PA, EPDM, etc.)
- Ceramic Materials (WC, TiN, SiC, BaTiO3, Al2O3, etc.)
- Composite Materials (FRP, PRM, M/P/C laminates, etc.)
- Thin-Film Materials
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Aerospace Industry
- We have successfully completed more than a hundred failure analysis projects for the aerospace industry including investigations on failed HPT blades, HPC blades, vanes, fan blades, rotor disk, stator, rotor bearing, starter shaft, oil duct, main landing-gear & nose landing-gear components, balance rudder, exhaust nozzle, engine mount, crashed helicopter, elevator of helicopter, etc.
Material and process evaluations to prevent special failure mechanisms such as hydrogen embrittlement (HE), hydrogen-induced cracking (HIC), stress corrosion cracking (SCC) and corrosion fatigue (CF), creep damage, etc.
Amusement Industry
- Our failure analysis projects for the amusement industry includes investigations on cracked roller coaster rail, shafts of vehicles, welded steel structure of vehicles, brakes, etc.
- Material and process evaluations to prevent improper design and manufacturing process which may result in special forms of damages such as hot cracking, fatigue cracking, pitting, intergranular attack, brittle cracking, etc.
Automotive Industry
- TÜV SÜD FA services can help in the investigation of failures involving horns, head lightings, steering wheels, tires, exploded air-compressors, PCBAs of automobiles, etc.
Material and process evaluations to prevent special forms of damage such as galvanic corrosion, pitting corrosion, intergranular attack, stress corrosion cracking (SCC), hydrogen embrittlement (HE), arcing, etc.
Chemical Industry
- TÜV SÜD’s FA services for chemical (including oil refinery & petrochemical) industry includes investigations on various failed devices such as high-T & high-P reactors, heat-exchangers, boilers, economizers, pumps, tanks, valves & piping, hydrogen furnaces, composite tanks and piping for concentrated acids /caustics, etc.
Material and process evaluations to prevent special forms of corrosion such as pitting corrosion, intergranular attack, stress corrosion cracking (SCC), corrosion fatigue (CF), firing, explosion, etc.
Construction & Infrastructure Industry
- TÜV SÜD’s FA services for construction and infrastructure industry including investigation on failed lifting equipment, steel wire ropes, welded steel structures, aero-platform, scaffolds, tower cranes, caterpillar cranes, piling machines, man-lifts, copper pipes & fittings, cast iron pipes & fittings, window frames, window glass, tempered glass panels,metallic decorations, marble/granite/ceramic tiles, paintings, etc.
Material and process evaluations to prevent special forms of damage such as pitting corrosion, intergranular attack, discoloration, stress corrosion cracking (SCC), aging, thermal shock, etc.
Consumer Products Industry
- We have completed more than hundred failure analysis projects for consumer products industry including investigations on failed computers, printers, switches, cables, electric fans, batteries, bicycles, fasteners, TV set components, hand phone components, furniture, various metal products and semi-products, etc.
Material and process evaluations to prevent special forms of damage such as pitting corrosion, intergranular attack, discoloration, stress corrosion cracking (SCC), aging, circuit open, short cut, arcing, fire incident, etc.
Food Industry
- TÜV SÜD’s FA services for food industry includes investigations on contamination/foreign objects in milk powder, contamination/foreign objects in quick meal products, food cans, aluminum foils for food package, polymeric pail/spoon for food products, etc.
Material and process evaluations to prevent special forms of damage such as contamination, pitting corrosion, intergranular attack, filiform corrosion, improper management etc.
Healthcare Industry
- TÜV SÜD’s FA services for healthcare industry includes investigations on failed medical devices for heart operation (e.g. guide-wires, venous return cannula, etc.), stainless steel needles, different polymeric cannula, fitting luer, pressure tubing, PA catheter, uniject, laryngeal mask, clamshell of laryngeal mask, surgical-implant parts, surgical equipment, pharmaceutical devices, etc.
Material and process evaluations to prevent special forms of damage such as contamination, pitting corrosion, intergranular attack, discoloration, stress corrosion cracking (SCC), poor workmanship, aging, etc.
Electronics Industry
- TÜV SÜD’s FA services for electronics industry including investigations on various IC chips, PCBs, PCBAs, multiple-layer capacitors, resistors, computers, hand phone sets, electrical cables, insulators, antennas, satellite ground station equipment, etc.
Material and process evaluations to prevent special forms of damage such as galvanic corrosion, pitting corrosion, intergranular attack, stress corrosion cracking (SCC), hydrogen embrittlement (HE), arcing, insufficient etching-back, etc.
Marine Industry
- We have completed more than hundred failure analysis projects for marine industry including investigation on failed ship main engines, generators, turbochargers, gearboxes, propeller shafts, propeller bearings, crankshaft, engine bearings, con-rod & piston & cylinder liner system, cylinder headers, engine block, submarine engines, submarine battery, piping & valves, hovercraft engine, ship-lifting systems, port cranes, off-shore rigs, sub-marine power cables, oil-tanker structures, ship hull structures, winch, underwater painting, diving equipment, etc.
- Material evaluations to prevent special form of corrosion including pitting corrosion, intergranular attack, stress corrosion cracking (SCC), corrosion fatigue (CF), bio-fouling, excessive CP, fire and/or explosion incident, etc.
Power & Energy Industry
- TÜV SÜD’s FA services for power & energy industry including investigations on failed boilers, gas turbine components, steam turbine components, combustion chambers, generator rotor shaft, air pre-heater, economizers, different power cables, fuel pumps, electric distribution equipment, transformer, switch gears, control panels, oil & gas exploration equipment (drilling machine), gas piping, wind turbine bearings, oil tanker structures, floating hoses, UPS system, etc.
Material and process evaluations to prevent special forms of damage such as high-T oxidation, High-T sulfidation, hot corrosion, pitting corrosion, intergranular attack, corrosion fatigue (CF), stress corrosion cracking (SCC), fire and/or explosion incident, etc.
Rail Industry
- TÜV SÜD’s FA services for rail (including land transport) industry including investigations on cracked rail, corroded rail, failed train gearbox, accident of train overhead collection system (OCS), accident of third rail system, surge arresters, corroded MRT station structures, tunnel equipment & structures, etc.
- Material evaluations to prevent special forms of damage such as rolling-contact fatigue, pitting corrosion, intergranular attack, stray-current corrosion, stress corrosion cracking (SCC), corrosion fatigue (CF), flashover, fire incident, etc.