FAQ - Damage Analysis at Fraunhofer IWM

What We Analyze

1. What types of damage cases are investigated?

Fraunhofer IWM analyzes damage to metallic, polymer, ceramic and composite materials, as well as glass—ranging from individual components to complex systems. Typical damage cases include:

• Fractures and cracks—brittle fracture, vibration-induced fracture, fatigue fracture, creep damage
• Plastic deformation and distortion—overload failure, creep damage
• Corrosion and surface damage—pitting, stress corrosion cracking, intergranular corrosion, coating delamination
• Wear and friction damage—abrasion, adhesion, erosion, tribo-oxidation
• Manufacturing and material defects—sink marks, porosity, weld defects, delamination and heat treatment defects

A wide range of services is available, from urgent damage investigations and consulting to materials testing and analysis using numerical simulation. If necessary, experts experimentally determine the causes of damage and verify them by calculation; future load limits can be quantified.

2. For which industries is failure analysis offered?

Fraunhofer Institute for Mechanics of Materials (IWM) supports companies— , among others—from the following industries:

Inquiries from other industries are always welcome and the team is committed to exploring how assistance can be provided.

3. What is the goal of a failure analysis?

The focus is on identifying the primary cause(s) of damage and the relevant influencing factors. Based on this, the Fraunhofer Institute for Mechanics of Materials (IWM) supports industry in:

• preventing future damage and reducing complaint-related costs
• optimizing design, material selection and manufacturing processes,
• assessing risks—remaining service life, safety margins and continued-operation conditions,
• resolving liability and warranty issues with suppliers, customers or insurance companies
• improving testing strategies and quality concepts.

Failure analysis is not an end in itself, but rather a potential starting point for sustainable product and process improvements.

Preparation and Procedure

4. How does a failure analysis typically proceed?

The process is generally divided into six steps:

1.      Initial Consultation and Case Documentation—Description of the failure event, components, operating conditions and objectives; a Non-Disclosure Agreement (NDA) may be signed in advance upon request.

2.      The investigation often begins with the client sending representative damaged parts to assess the damage and serve as the basis for the initial investigation step

3.      Visual Inspection and Documentation—photographic documentation, description of the damage pattern, initial hypotheses.

4.      Investigation Strategy—Selection of suitable testing and analysis methods; test concepts and simulation approaches as needed.

5.      Conducting the Investigations—materials science, mechanical, corrosion and, if necessary, numerical analyses—all from a single source.

6.      Evaluation and Interpretation—identification of the cause(s) of the damage; quantification of relevant influencing factors.

7.      Recommendations for Action—including specific measures.

8.      Optional Expert Report—scientifically sound expert report

Upon request, interim meetings and status updates at defined milestones are possible.

5. What information is required to conduct a meaningful analysis?

The following information is particularly valuable:

• Description of the damage—time, operating conditions, frequency and environment
• Photos of the component and the damaged area (ideally before any further processing)
• Design drawings, specifications, material data, tolerances
• Manufacturing and processing history—heat treatment, surface treatment, welding methods
• Service history—load profile, operating time, media, temperatures
• Components—damaged parts and, if possible, an undamaged reference part
• Previous investigations or hypotheses

The more complete the information, the more efficient the analysis will be. Any missing details will be clarified during the initial consultation.

6. May the component be cleaned, disassembled or further examined in advance?

Please consult us before any cleaning, disassembly or further processing. Damaged components should remain in their original condition. Cleaning, disassembly or further processing can irretrievably destroy important traces—such as discoloration, deposits, fracture surfaces and oxidation zones.

Please contact the laboratory before taking any further steps. Together, the laboratory and the customer will determine:

• How to document and secure the component,
• whether and to what extent disassembly is possible
• how to package and transport it properly,
• and what photos and accompanying information should be sent in advance.

If in doubt, follow this rule: Take photos and maintain the object in its current state.

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Methods and Scope of Services

7. What testing methods are used?

Fraunhofer Institute for Mechanics of Materials (IWM) offers a wide range of modern testing and analysis methods:

Microscopy and Microstructural Analysis

• Optical microscopy (OM), confocal laser scanning microscopy
• Scanning electron microscopy (SEM) including energy-dispersive X-ray spectroscopy (EDX) and electron backscatter diffraction (EBSD) analysis
• Metallography, specimen preparation and microstructural evaluation
• Hardness testing (Vickers, Rockwell and Brinell)
• Fractography (fracture surface analysis)

Optical surface contour and structure analysis, surface analysis

• Scratch tester (adhesion test)
• Roughness and topography measurement (Atomic Force Microscopy (AFM), white-light interferometry)
• Confocal surface…
• Focus variation

Chemical and structural analysis

• X-ray diffraction (XRD) for phase and residual stress analysis
• Energy-dispersive X-ray spectroscopy (EDX) for elemental analysis, chemical analysis for contamination determination
• Fourier transform infrared (FTIR) and Raman spectroscopy
• XPS Analysis

Mechanical Testing

• Tensile, compressive, bending and hardness (Vickers, Rockwell, nano- and microhardness)
• Fatigue and creep tests, thermomechanical testing
• Fracture mechanics testing (K_Ic, crack propagation tests)

Tribology

• Pin-on-disk, oscillatory wear, friction and wear measurement

Corrosion and environmental testing

• Salt spray, cyclic environmental testing and exposure to media
• Electrochemical methods (potentiodynamics, electrochemical impedance spectroscopy (EIS))

Numerical Simulation

• Finite Element Method (FEM)—stress, deformation and life cycle analyses
• Fracture mechanics simulation, crack propagation modeling
• Molecular dynamics (MD) and multiscale modeling approaches

The methods are always selected on a case-by-case basis and tailored to specific objectives—combining experimentation and simulation.

8. Does the Fraunhofer IWM also assist with service life estimation and reliability assessment?

Yes. Damage analysis and service life assessment are closely linked at Fraunhofer IWM. Support is provided:

• in estimating the remaining service life of cracked or damaged components (fracture mechanics approaches according to Linear Elastic Fracture Mechanics (LEFM) and Elastic-Plastic Fracture Mechanics (EPFM)),
• in designing test programs for service life and reliability assessment
• in the creation of Wöhler curves and load collectives as well as their interpretation
• in applying test results to real-world operating conditions and safety verifications
• and in deriving safety margins for decisions regarding continued operation.

In this way, a single damage event gives rise to a comprehensive reliability and service life concept.

9. Is support also provided for implementing the derived measures?

Yes. Upon request, Fraunhofer Institute for Mechanics of Materials (IWM) supports projects beyond the root cause analysis:

• Consulting—contributing expertise in materials mechanics
• Perform a system analysis and define stress limits
• Design optimization—geometries, notches, wall thicknesses and joint locations
• Material selection and qualification—Comparison and validation of alternatives
• Process optimization—manufacturing, heat treatment and surface treatment
• Adaptation of testing and quality strategies—development of test plans, defect detection limits
• Validation and verification tests—confirmation of the effectiveness of implemented measures
• The process includes developing practical corrective actions in close collaboration with customers and providing support for their individual implementation.

Upon request, support is provided from the initial damage assessment through to verified implementation.

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Costs, Duration and Urgency

10. How are costs and processing time determined?

Costs and duration depend on:

• the complexity of the damage case and the number of components to be examined,
• the methods used—screening, in-depth laboratory analysis or simulation,
• the need for supplementary tests or, if necessary, simulation efforts

Typical process:

1.      Initial free assessment based on the provided documentation (photos, description, drawings, damaged part)

2.      Quote including a description of the procedure, timeline and transparent cost estimate

3.      Optional: phased approach—e.g., basic screening → targeted in-depth analysis

Urgent inquiries can be addressed within a few days. More extensive, complex inquiries regarding damage remediation—which may include test programs—typically take anywhere from weeks to months.

11. Is support available on short notice for cases of acute damage?

Yes. In urgent cases—such as production shutdowns, product recalls or safety-related failures—the team will consider prioritizing the case. Together, the team will clarify:

• urgency, risks and decision deadlines,
• the minimum scope required to ensure short-term confidence in action (rapid preliminary analysis),
• and a timeline for a subsequent in-depth analysis, if necessary.

For urgent cases, please contact us directly by phone. Freiburg: +49 761 5142-0, info@iwm.fraunhofer.de

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Results and Reports

12. What reports and expert opinions will be provided?

Fraunhofer IWM prepares technical and scientific reports that include the following elements:

• Description of the damage incident and the investigation strategy
• Documentation of all analyses (images, measurement data, evaluations)
• Interpretation and evaluation of the results
• Determination of the cause(s) of the damage and influencing factors
• Specific recommendations for action

Reports are provided in German by default and are also available in English upon request. Upon request, reports can also be tailored for non-specialists—e.g., for management decisions or supplier meetings.

13. Are expert reports that are admissible in court prepared?

Technical and scientific expert reports are prepared that serve as a sound basis for:

• Internal decisions and management communication
• Supplier and customer complaints
• Insurance and liability clarifications
• Technical basis in disputed or legally relevant proceedings

The Fraunhofer Institute for Mechanics of Materials (IWM) collaborates with legal advisors to clarify the admissibility of its reports in specific proceedings. As a scientifically independent institution, Fraunhofer IWM offers particular credibility in challenging situations. If required, Fraunhofer IWM provides an expert report from a publicly appointed and sworn expert in metallic materials and engineering ceramics.

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SMEs and Collaborations

14. Can small and medium-sized enterprises (SMEs) also take advantage of the services?

Yes, absolutely. Many SMEs lack their own materials science infrastructure—Fraunhofer IWM therefore provides support. The institute offers:

• Modular service components, scalable based on the specific issue and budget,
• Low-threshold initial assessment based on photos and a brief description—specialized knowledge is optional,
• Communication support with suppliers, customers and insurance companies,
• Individual services—mechanical testing, metallography, simulation or corrosion testing—can also be ordered separately.

Photographs and a few sentences describing the situation often suffice for an initial assessment.

15. What cost-effective entry-level options are available for small and medium-sized enterprises (SMEs)?

Tiered service packages deliver reliable results even on a limited budget:

16. Are framework agreements and long-term partnerships also offered?

Yes. For companies with recurring analysis needs, the company offers:

• Framework agreements with defined response times and standardized processes,
• Dedicated points of contact for efficient, routine communication and consulting services
• Research collaborations—if a specific issue arising from a damage case leads to a broader research question, this can be pursued bilaterally or through funded projects (such as Bundesministerium für Bildung und Forschung (BMBF), European Union (EU)),
• Joint training sessions sustainably strengthen internal expertise.

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Why Fraunhofer IWM?

17. What advantages does collaborating with Fraunhofer IWM offer compared to an engineering firm or testing laboratory?

In detail:

1.      Scientific depth and state-of-the-art methods—Fraunhofer Institute for Structural Durability and System Reliability (IWM) conducts ongoing research into failure and material mechanisms. The latest findings directly enrich each analysis—particularly valuable for novel materials, complex operating conditions and safety-critical applications (e.g., medical engineering, aviation).

2.      A Unique Combination: Experiment and Simulation—Experimental and, when required, computational methods verify causes of damage; further questions and potential solutions can be evaluated using both experimental methods and simulation.

3.      Comprehensive infrastructure from a single source—from microstructural evaluation, scanning electron microscopy (SEM) analysis, fracture mechanics modeling and component testing to finite element method (FEM) simulation across all scales (from the atomic level to the component level)—all under one roof.

4.      Scientific independence—Fraunhofer IWM is product- and vendor-neutral. This is particularly important when multiple parties are involved or when expert opinions are to serve as the basis for resolution in disputed cases.

5.      Fraunhofer Network—when required, complementary expertise is integrated. Close contacts can be activated at short notice after consultation.

6.      From Analysis to Improvement—A failure case becomes the impetus for sustainable product and process optimization. The institute serves as a competent partner for development processes that extend beyond the specific failure case.

7.      Confidentiality—The institute treats everything from the initial inquiry to the final solution with the utmost confidentiality. If required, the institute will enter into a mutual confidentiality agreement.

When results are available but further clarification is required, solutions are needed, possible approaches must be evaluated or material science consulting is required, support is provided through expertise and experience in materials science and testing.

18. Can examples be provided of how a failure analysis has led to specific improvements?

Example 1 – Breakage of a Drive Shaft (Mechanical Engineering)  

Failure Analysis → Fatigue failure due to unfavorable notch geometry and improper heat treatment → Geometric optimization and adjusted heat treatment parameters → Failure rate significantly reduced; service life significantly extended.

Example 2 – Corrosion damage to a piping system (process industry)  

Failure analysis → Detection of stress corrosion cracking under specific process conditions → Change in material and adjustment of operating conditions → Downtime greatly reduced, consequential damage avoided.

Example 3 – Cracking in a medical device component (medical engineering)  

Failure analysis → Combined effect of manufacturing-induced residual stresses and cyclic loading → Manufacturing optimization and additional interim inspection → Increased reliability and support for regulatory documentation (MDR).

Example 4 - Lubricant degradation in a small gearbox (Automotive) 

Failure analysis → Detection of changes in the lubricant used → Lubricant change and prevention of contamination → Increased service life and reliability.

Example 5 – Leak in a pipeline (process engineering) 

Failure analysis → stress corrosion cracking caused by aggressive media and mechanical stresses → change of materials to a corrosion-resistant alloy and optimization of the pipeline routing → downtime and repair costs drastically reduced.

Example 6 – Vibration-induced fracture in a pump housing (chemical plant engineering) 

Failure analysis → Resonant vibrations caused by insufficient damping and flow-induced forces → Structural modifications to avoid critical natural frequencies and installation of vibration dampers → Operational safety significantly increased.

Example 7 – Cracking in a gas turbine blade (energy engineering) 

Failure analysis → Thermal fatigue due to cyclic high-temperature loading and oxidation-induced degradation of the materials → Optimization of the cooling channel geometry and use of oxidation-resistant thermal insulation layers → Operating temperature safely reduced & maintenance intervals extended.

Example 8 – Cracking in a pressure vessel (process engineering) 

Failure analysis → Hydrogen embrittlement under a high-pressure hydrogen atmosphere → Use of hydrogen-resistant steels and optimized post-weld heat treatment → Safety margin significantly increased.

Example 9 – Failure of a ball bearing in a transmission (automotive engineering) 

Failure analysis → Seizure caused by mixed friction and insufficient oil supply → Optimization of lubricant viscosity and surface treatment of the running surfaces → Service life significantly increased.

Example 10 – Fracture of a connecting rod (automotive engineering) 

Failure analysis → High cyclic bending stresses and material inhomogeneities → Optimization of the forging process and ultrasonic testing of the blanks → Risk of failure minimized.

A thorough failure analysis generally provides substantial cost savings when compared with the follow-up costs of an unresolved problem.

19. Does Fraunhofer IWM also collaborate with other research institutes?

The Fraunhofer IWM maintains extensive connections within the Fraunhofer network and collaborates with universities, colleges and non-university research institutions.

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Knowledge and Continuing Education

20. Are training courses or workshops on failure cases offered?

Yes. Upon request, Fraunhofer IWM offers customized training and workshop formats on damage cases and the following topics, such as:

• Typical failure mechanisms in metals, polymers, composites, glass and ceramics
• Friction and wear, tribology in applications
• Component design optimized for materials and loads
• Interpretation of failure analyses and expert reports within the company
• Systematic error prevention (lessons learned, root-cause analyses)
• Establishing internal processes for damage documentation and evaluation

Training sessions and workshops on specific topics can be conducted on-site.

Formats range from short technical presentations (2 to 4 hours) to multi-day, practice-oriented seminars. Content is tailored to the industry, the product portfolio and the employees’ prior knowledge.

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Contact

Fraunhofer Institute for Mechanics of Materials IWM

Wöhlerstraße 11 | 79108 Freiburg im Breisgau Phone: +49 761 5142-0 | Fax: +49 761 5142-510

Email: info@iwm.fraunhofer.de Website: www.iwm.fraunhofer.de (http://www.iwm.fraunhofer.de/)

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