Topic 5
5.1 Engineering Products
Engineering Products
An engineering product is designed and
manufactured to perform specific functions over a
period of service life.
Engineering Service /
Manufacturing
Design Performance
5.1 Engineering Products
Engineering Products
Engineering Design
Engineering design is essentially a decision-making
process by which a product can be manufactured at
a reasonable cost.
Differences in design, which will affect performance,
can be related to the extent of engineering analysis
made by the designer. Parameters included in such
analysis are:
Geometry and dimensions of different parts
Types of materials used and their specifications
Fabrication and assembly techniques
Service conditions
5.1 Engineering Products
Engineering Products
Manufacturing
Once the engineering drawing for the product is
developed, specifying the design parameters, a
prototype is made and tested.
Where necessary, further modification of the design
is made so that the product meets specification.
Then the design is materialised into a commercial
product by a manufacturer.
The material selected usually governs the
manufacturing process.
5.1 Engineering Products
Engineering Products
Service Performance
Once commercialised, the product goes into service
to meet its functional requirements.
Operating procedures to start-up and shut-down,
maintenance procedures and maintenance schedule
should also be specified.
5.2 Failure of Engineering Products
Failure Analysis
Systematic process Failure Analysis is
of examining the designed to:
failed component to Identify Failure Mode
determine the root the way it failed
cause of failure and Identify Failure Site
to use such where failure initiated
information to Identify Failure
Mechanism physical
eventually improve phenomena of the
reliability. failure
Determine the Root
Cause design, defect
or loads that lead to
failure
Recommend Failure
Preventive Measures
5.4 Failure Analysis Procedure
1. Background Information
Obtain the history of the component, including
manufacturing history and details of the failure.
Some important information about the
component:
Location, Name of component, Identification no.
Owner, User, Manufacturer
Function of item
Service life time in service, operating conditions
(stress, temperature, environment)
Material used, Specifications properties, heat
treatment
Manufacturing techniques, Specifications and codes
Fabrication procedures welding, bolting, adhesive
joining
Quality control reports during manufacturing, Service
and Maintenance records
5.4 Failure Analysis Procedure
1. Background Information
Some important information about the failure:
Date and time of failure, Temperature, Environment
Extent of damage, Sequence of failure, Injuries
Stage of operation when failure occurred
Drawings, photographs of failure and adjacent
areas
Any service deviations that might have contributed
to failure
Observations by operating personnel on the failure
5.4 Failure Analysis Procedure
4. Metallurgical Examination
For fractured components, macro-examination of
fracture may be insufficient to properly evaluate the
fracture modes. Hence micro-fractographic
examination via the use of Scanning Electron
Microscope (SEM) is often necessary.
As fracture surfaces are
irregular in shape (rough), the
SEM is used as it provides an
excellent depth of field and
resolution over normal optical
light microscopes.
In addition, when the SEM is
fitted with an energy dispersive
spectrometer, elemental
analysis of the fracture surface
can be performed. This is useful
in analysing inclusions, foreign
material or corrosion products
on the fracture surface.
5.4 Failure Analysis Procedure
4. Metallurgical Examination
From micro-fractography, it is possible to:
Study the rate of progress of the fracture
Characterise the ductility / brittleness of the material
Determine the fracture mechanism
Brittle fracture
4. Metallurgical Examination
Examination of the microstructure of the material is
also necessary to understand the properties of the
material.
Microstructural examination involves cutting the
sample, mounting, grinding, polishing and etching so
as to reveal its structure for observation under light
optical microscope.
4. Metallurgical Examination
The microstructure of a material
affects the properties and
behaviour of the material.
Through microstructural
examination, errors in material
processing, heat treatment, surface
treatment and welding can be Welding cracks
revealed.
The microstructure of a material
also helps in determining what
processing methods and
treatments were actually performed
on the component, whether
processing steps were omitted or
incorrectly done.
SCC in stainless steel
5.4 Failure Analysis Procedure
5. Chemical Analysis
Chemical analysis is used to determine whether the
material grade used is indeed as specified for the
component.
Wrong material could be used as mixed up can occur
at the mill, warehouse or manufacturing plant.
6. Mechanical Tests
Mechanical properties of materials
need to be determined to establish
whether they are capable of
withstanding the loads applied
during operation.
Mechanical properties would include
hardness and other related to the
failure, such as toughness, fatigue,
creep strength etc.
There are many international test
procedures for establishing Tensile test
mechanical properties, and these
should be used. The measured
properties are to be compared to the
specifications and to typical property
data for the grade to reveal any
abnormality.
5.4 Failure Analysis Procedure
Failure Analysis
Performing failure analysis is a very challenging and
exciting job. The investigator must have a sound
background in the areas that are central to the testing
and analytical work.
Analysis of failures over the years has expanded the
practical knowledge for processing and product
development, and also contributed to basic scientific
insights.
Most failures could easily be prevented if well-
documented procedures and precautions are taken.