Practical Engineering Failure Analysis

Filling a gap in the literature, Practical Engineering Failure Analysis vividly demonstrates the correct methodology to conduct successful failure analyses, as well as offering the background necessary for these investigations. This authoritative reference covers procedures to reduce the occurrence of component failures due to errors in material se

Applied Engineering Failure Analysis: Theory and Practice provides a point of reference for engineering failure analysis (EFA) cases, presenting a compilation of case studies covering a 35-year period, from the 1970s to 2012. This period spans the era from the time when slide rules were used routinely for engineering calculations, and when har

Component failures result from a combination of factors involving materials science, mechanics, thermodynamics, corrosion, and tribology. With the right guidance, you don’t have to be an authority in all of these areas to become skilled at diagnosing and preventing failures. Based on the author’s more than thirty years of experience, Practical Plant Failure Analysis: A Guide to Understanding Machinery Deterioration and Improving Equipment Reliability is a down-to-earth guide to improving machinery maintenance and reliability. Illustrated with hundreds of diagrams and photographs, this book examines... · When and how to conduct a physical failure analysis · Basic material properties including heat treating mechanisms, work hardening, and the effects of temperature changes on material properties · The differences in appearance between ductile overload, brittle overload, and fatigue failures · High cycle fatigue and how to differentiate between high stress concentrations and high operating stresses · Low cycle fatigue and unusual fatigue situations · Lubrication and its influence on the three basic bearing designs · Ball and roller bearings, gears, fasteners, V-belts, and synchronous belts Taking a detailed and systematic approach, Practical Plant Failure Analysis thoroughly explains the four major failure mechanisms—wear, corrosion, overload, and fatigue—as well as how to identify them. The author clearly identifies how these mechanisms appear in various components and supplies convenient charts that demonstrate how to identify the specific causes of failure.

Failure analysis is the preferred method to investigate product or process reliability and to ensure optimum performance of electrical components and systems. The physics-of-failure approach is the only internationally accepted solution for continuously improving the reliability of materials, devices and processes. The models have been developed from the physical and chemical phenomena that are responsible for degradation or failure of electronic components and materials and now replace popular distribution models for failure mechanisms such as Weibull or lognormal. Reliability engineers need practical orientation around the complex procedures involved in failure analysis. This guide acts as a tool for all advanced techniques, their benefits and vital aspects of their use in a reliability programme. Using twelve complex case studies, the authors explain why failure analysis should be used with electronic components, when implementation is appropriate and methods for its successful use. Inside you will find detailed coverage on: a synergistic approach to failure modes and mechanisms, along with reliability physics and the failure analysis of materials, emphasizing the vital importance of cooperation between a product development team involved the reasons why failure analysis is an important tool for improving yield and reliability by corrective actions the design stage, highlighting the ‘concurrent engineering' approach and DfR (Design for Reliability) failure analysis during fabrication, covering reliability monitoring, process monitors and package reliability reliability resting after fabrication, including reliability assessment at this stage and corrective actions a large variety of methods, such as electrical methods, thermal methods, optical methods, electron microscopy, mechanical methods, X-Ray methods, spectroscopic, acoustical, and laser methods new challenges in reliability testing, such as its use in microsystems and nanostructures This practical yet comprehensive reference is useful for manufacturers and engineers involved in the design, fabrication and testing of electronic components, devices, ICs and electronic systems, as well as for users of components in complex systems wanting to discover the roots of the reliability flaws for their products.

This is a practical guide for those who do the work of maintaining and improving the reliability of mechanical machinery. It is for engineers and skilled trades personnel who want to understand how failures happen and how the physical causes of the great majority can be readily diagnosed in the field. It explains the four major failure mechanisms, wear, corrosion, overload, and fatigue and, using easy-to-read charts, how they can be diagnosed at the site of the failure. Then, knowing the physical failure mechanics involved, the reader can accurately solve the human causes. To improve the reader’s understanding, all the diagrams and most of the tables have been redrawn. The number of actual failure examples has been increased, plus the last chapter on miscellaneous machine elements includes new material on couplings, universal joints, and plain bearings. Features A practical field guide showing how to recognize how failures occur that can be used to solve more than 85% of mechanical machinery failures Incorporates multiple easy-to-follow logic trees to help the reader diagnose the physical causes of the failure without needing detailed laboratory analysis Explains how the mechanics, corrosion, materials science, and tribology of components can fit together to improve machinery reliability Includes more than 150 completely redrawn charts and tables, plus almost 250 actual failure photographs to help guide the reader to an accurate analysis Contains clear and detailed explanations of how lubricants function and the critical roles of corrosion and lubrication play in causing mechanical failures

Suitable for engineers, this work presents a tool for expert investigation and analysis of component failures. It is designed-to-be-used introduction to principals and practices. It includes: 500 illustrations; pinpoints fracture type with comparative fractographs; and can be used as expert examples in reports.

This book addresses the failures of structural elements, i.e. those components whose primary mission is to withstand mechanical loads. The book is intended as a self-contained source for those with different technical grades, engineers and scientists but also technicians in the field can benefit from its reading.

A practical and accessible approach to machinery troubleshooting Unique Methods for Analyzing Failures and Catastrophic Events is designed to assist practicing engineers address design and fabrication problems in manufacturing equipment to support safe process operation. Throughout the book, a wealth of real-world case studies and easy-to-understand illustrated examples demonstrate how to use simplified failure analysis methods to produce insights for a wide range of engineering problems. Dr. Anthony Sofronas draws from his five decades of industry experience to help engineers better understand the science behind a particular problem, evaluate the failure analysis of an outside consultant, and recommend the best path forward to management. The author distills sophisticated engineering analysis approaches into compact, user-friendly methodologies that can be easily applied to the readers’ own situations to avoid costly failures. Each chapter includes a thorough summary of the topic, relatable technical examples, and a concluding section with key takeaways and expert tips and advice. This invaluable guide: Helps readers make better decisions while solving complex engineering problems Provides numerous illustrated examples from engineering and science that can be used to develop real-world solutions Features detailed descriptions of both basic and advanced engineering analysis techniques Covers essential technical subjects that facilitate safe facility design and effective troubleshooting Unique Methods for Analyzing Failures and Catastrophic Events: An Illustrated Guide for Engineers is a must-have for chemical, petroleum, and mechanical engineers, reliability managers and technicians, design contractors, and maintenance workers working in process industries.