Failure Analysis and Investigation of Damage Mechanisms

We address the issues you face as a result of operational failures and quality assurance challenges in industrial manufacturing processes. The thorough investigation of damage to components and materials (including metals, ceramics, glass, and silicon) is a well-established practice at Fraunhofer IWM. For your specific project, we assemble a competent team that will work with you to discuss the next steps toward an effective solution. We understand how critical time is for you when investigating damage cases, and we handle every project flexibly, confidentially, and with a customer-focused approach. Based on your project requirements and a non-binding consultation, we will provide you with a quote promptly.

In very few cases does a single event lead to component damage — usually, multiple factors interact. In our damage analyses, we therefore not only examine the current damage pattern but also analyze the entire context on a case-by-case basis, including the materials, the process chain, and the operating conditions. We consider the key mechanical, thermal, corrosive, and tribological influencing factors as well as behavior in the presence of media. Please contact us. Together, we will find a customized solution for your specific needs.

Our goals are

• to prevent damage in a sustainable manner,
• to significantly reduce loss ratios,
• and to minimize the risks of damage occurring.

to top

Our Services

• We investigate the causes of technical damage to components and irregularities in processes, and identify the mechanisms of failure, fracture patterns, potential random events, stresses, overloads, defects in materials, and pre-existing damage.
• We test components and materials for compliance with specifications and standards.
• We simulate the operational loads on components and in model tests and evaluate the relevant influencing factors. This allows us to trace failure patterns or irregularities.
• We determine whether manufacturing and/or application errors are present.
• We develop proposals for adapting manufacturing processes and improving the mechanical durability of products.

to top

How We Work

• We understand how critical time is when investigating claims.
  • In urgent cases involving defective or failed components, we provide you with decision-making support on short notice, based on a robust assessment using specific analytical methods.
    
• We understand the (potential) legal and economic implications of technical damage.
  • In cases of major damage or damage to mass-produced products, the costs are often enormous, and court proceedings are frequently involved. Here, we support you by preparing well-founded expert reports or counter-reports and represent you in court as experts (some of whom are publicly appointed and sworn).
    
• We view damage cases as an opportunity for innovation
  • As part of medium-term projects, by evaluating your process chain and taking into account the materials used, we can provide you with suggestions for improvement to enhance product quality and optimize processes, in addition to a pure damage analysis.

to top

Our Methods for Materials Characterization and Analysis

• Microstructural Analysis (metallography, ceramography, crack and fracture surface evaluation, phase analysis)
• Materials Analysis (chemical and structural composition of materials)
• Characterization of materials and components
• Mechanical (static, cyclic, and dynamic impact)
  • Thermomechanical
  • Micromechanical
  • Chemomechanical
  • Thermophysical
• X-ray diffraction measurements of residual stresses
• Evaluation of corrosion stability, adhesion, catalysis, compatibility of materials, and diffusivity of component surfaces
• Evaluation of tribological pairings, determination of coefficient of friction, wear resistance, emergency running properties, lubricant stability, and fretting behavior
• Welding simulation and weld seam optimization

to top

Examples of damage we investigate

• Component damage to bearings, gearboxes, gears, and welds
• Quality variations resulting from production processes (e.g., forming, hardening, finishing, coating)
• Corrosion (materials, compatibility of materials, contact with media, etc.)
• Stress corrosion cracking
• Brittle fractures, taking into account the possible effects of hydrogen and corrosive media
• Fatigue fractures, taking into account all relevant factors
• Damage to components under pressurized hydrogen

to top

Possible causes of damage and failure that we observe

• Variations in the quality of batches of material that lead to failures during machining processes or in service.
• Improperly performed heat treatments, which, for example, lead to increased wear or surface spalling on gears, and in extreme cases, the shearing off of entire teeth,
• weld defects or hot cracks in welded joints, which result in fatigue cracks during operation,
• Microstructural changes in the heat-affected zone (HAZ) of aluminum alloys, which locally reduce mechanical properties,
• Errors in process control during case hardening of steels or during the electroplating of coatings, resulting in hydrogen embrittlement and fractures,
• Unfavorable combinations of materials that cause premature failure due to contact corrosion through direct contact (such as a combination of steel and aluminum alloy),
• Unfavorable selection of materials that leads to pitting corrosion under operating conditions

to top