Failure Analysis / Investigation

LMATS provides failure investigation and failure analysis services and various laboratory based metallurgical tests from its several Australian Laboratories. LMATS comprises a team of experienced Materials Engineer, Metallurgist, Scientist, Engineering Technologist, AICIP/NACE/WTIA/AINDT Inspectors and Non-destructive Testing personnel. The combination of these professionals from different speciality ensures that the most probable root cause is concluded and the best preventive measures are recommended.

 

Additionally, the end user is benefited by implementation of the most cost-effective condition monitoring regime that will comply with the regulatory requirements, various international Standards and extend your asset life.  Any extension of asset usage beyond its design life contributes in reducing the environmental impact.

 

LMATS is accredited in accordance with ISO 17025 in several metallurgical, mechanical, chemical and NDT related tests. LMATS Forensic Engineers (Investigators) performing failure analysis are also authorised under ISO 17025 Accreditation system to perform other types of engineering tests. This additional experience and qualification of LMATS Materials Engineers assist LMATS clients the added value to their asset life extension.

Considering LMATS extensive experience in various fields, LMATS also offers EXPERT WITNESS for third party audit or dispute resolution or litigation purposes. As an Expert Witness, LMATS team can provide an independent Opinion about a subject matter or a consumer product, technical adviser for vendor qualification or approval, conformance to industry specifications or a forensic review.

 

Failure analysis is a process of collecting and analysing facts or data to determine a probable root cause of a failure. This involves collecting data about operating conditions, visual examination of the failed product or component, fractography, non-destructive testing, evaluation of mechanical and chemical properties, metallography-microscopy, spectroscopy, analysis of the facts and findings, root cause conclusion and recommendations to prevent the failure from recurring. This process is very vital for heavy industries to prevent failure of affordable and unaffordable components which can cost loss of production in thousands to millions of dollars or injuring person or community. The process of identifying the root cause and implementing preventive actions reduces the risk of injuries, reduces the downtime and increases productivity in the mining industries, Oil & Gas, offshore and shipping industry and heavy engineering industries. Most of the quality endorsed organisations and insurance companies ensure that failure investigations are performed to reduce the risk of failure in future. 

 Overload fractured shaft  

A failure is evident when a component is unsafe to be used in normal operating conditions. Generally, it has become completely or partially unusable or has deteriorated to the point that it is undependable or unsafe for normal sustained service. There are several modes of Failures. Some of the common modes of failures are

  • Fatigue failure
  • Overload failure
  • Erosion and Wear failure
  • Various forms of Corrosion failure
  • Dezincification,
  • Graphitisation, SSC, HIC, etc
  • Sensitization of stainless steel
  • Stress corrosion cracking
  • Ductile and brittle fractures
  • Hydrogen embrittlement
  • Liquid metal embrittlement
  • Creep and stress rupture

    

Some of the common causes of failures are

  • Incorrect material used
  • Manufacturing defects e.g. Casting, forging, welding discontinuities
  • Incorrect heat treatments
  • Product not manufactured to the Design requirements.
  • Machining or fabrication tolerances not achieved
  • Inadequate environmental protection/control
  • Inadequate maintenance
  • Overloading or incorrect use
  • Assembly errors
  • Design errors
  • Unforeseen operating conditions

 

LMATS has completed Failure Analysis and investigation on several types of materials, components and product for various industries. Some of the common examples are

  • Heat Exchangers from Oil & Gas, Refineries, Power Generation, Paper mills, Chemical plants
  • Various automotive and Locomotive parts e.g. Wheels, steering, gears, axles, engine block, Crack shaft, Connecting rods, fuel lines, etc
  • Various Aerospace parts e.g. Landing gear, trunnion, Fuel lines, Fuel pumps, Universal column, etc
  • Power station – Boiler wall tubes, valves,
  • Pressure vessel and pipes – Aluminium Smelter
  • Various fabricated joints and welded assemblies, thermit welds
  • Various Rolling stock components – Train wheels, Rails, Rail welds, Bogies, couplers, etc
  • Cooling Towers parts – Caster bolts, valves, tubes, etc
  • Water industry parts – Valves, pipes, dam hydraulics,
  • Long distance pipelines – Ammonia export line, White oil transfer line, gas transmission
  • Fasteners – Bolts, nuts, studs, assemblies, etc
  • Various mining related components and assemblies.

Contact one of the Australia wide LMATS Laboratories near you to obtain specialist advice on your requirements. Currently LMATS provides failure investigation and analysis services in VIC Victoria, NSW New South Wales, QLD Queensland, NT Northern Territory, WA Western Australia, SA South Australia, TAS Tasmania and some of the international locations as per client’s requirements. LMATS NATA accredited laboratories are in Melbourne, Sydney, Albury, Brisbane and Perth.