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Introduction to Failure Analysis and Prevention

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Abstract

This article briefly introduces the concepts of failure analysis, including root-cause analysis (RCA), and the role of failure analysis as a general engineering tool for enhancing product quality and failure prevention. It initially provides definitions of failure on several different levels, followed by a discussion on the role of failure analysis and the appreciation of quality assurance and user expectations. Systematic analysis of equipment failures reveals physical root causes that fall into one of four fundamental categories: design, manufacturing/installation, service, and material, which are discussed in the following sections along with examples. The tools available for failure analysis are then covered. Further, the article describes the categories of mode of failure: distortion or undesired deformation, fracture, corrosion, and wear. It provides information on the processes involved in RCA and the charting methods that may be useful in RCA and ends with a description of various factors associated with failure prevention.

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Acknowledgments

This article was revised from J.J. Scutti and W.J. McBrine, “Introduction to Failure Analysis and Prevention,” Failure Analysis and Prevention, Volume 11, ASM Handbook, ASM International, 2002, p 3–23. The authors gratefully acknowledge the contribution of Mr. Joe Epperson, FASM, National Transportation Safety Board, Retired, to the section “Failure Definitions” in this article.

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Authors and Affiliations

  1. Professional Analysis and Consulting, Inc, Sugar Grove, Illinois, USA

    Roch J. Shipley

  2. IMR Test Labs, Louisville, Kentucky, USA

    Brett A. Miller

  3. Engineering Systems Inc, Norcross, Georgia, USA

    Ronald J. Parrington

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  1. Roch J. Shipley
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  2. Brett A. Miller
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  3. Ronald J. Parrington
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Correspondence to Ronald J. Parrington.

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© 2021 ASM International. This article is reprinted with permission from Failure Analysis and Prevention, Vol 11, 2021 ed., ASM Handbook, Brett A. Miller, Roch J. Shipley, Ronald J. Parrington, and Daniel P. Dennies, editors, ASM International, 2021, p 3–24, https://doi.org/10.31399/asm.hb.v11.a0006753.

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Shipley, R.J., Miller, B.A. & Parrington, R.J. Introduction to Failure Analysis and Prevention. J Fail. Anal. and Preven. 22, 9–41 (2022). https://doi.org/10.1007/s11668-021-01324-2

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