MS&T '08 Short Course

Failure Analysis Methodology and Case Histories
October 9-10 • 8:30 a.m. to 4:30 p.m.

Location:         Hilton Pittsburgh
Fee:                 $425 Member; $528 Nonmember; $159 Student
Instructor:    Mehrooz Zamanzadeh, Ph.D., FASM, FNACE; Matco Associates

Course Overview
Root cause failure analyses methods are presented and illustrated using case studies. Careful site documentation, evidence preservation and the acquisition of design, fabrication, maintenance and operational data are discussed. Laboratory evaluation and test techniques for determining the root cause of failure are provided.

Learning Objectives
Upon completion of this course, participants will be able to:

• Demonstrate general procedures, techniques and precautions in failure analysis;
• Describe the many interrelated factors involved in examining a fracture;
• Identify the basic fracture modes and their characteristics, including the factors affecting ductile-brittle relationships;
• Describe typical fatigue characteristics and how to identify them.

Who Should Attend?

• Engineers: design, quality, manufacturing or materials
• Managers: design, quality, manufacturing, plant or systems
• Technicians: experienced (15 year minimum) materials, mechanical, inspection or quality
• Scientists: reliability, stress analysis or fracture mechanics
• Specialists: maintenance, warranty or customer service

Course Outline

1. Introduction

1. History
2. Failures are caused by human errors.
3. Causes of failures
4. Product specifications and failures
5. Root cause failure analysis
6. Failure mode and effects analysis
7. Sequence of events analysis
8. Forensic engineering

2. Types of failures

1. Ductile fracture
2. Brittle fracture
3. Fatigue fracture
4. Corrosion failures
5. Coating failures
6. Concrete failures

3. How to conduct a failure analysis

1. Determine when, where and how the failure occurred
2. Photographic documentation
3. Visual examination
4. Collect samples for lab investigation
5. Identify defects nondestructively
6. Conduct appropriate chemical analysis
7. Confirm material composition and identify contaminants through EDS and AES analysis
8. Analyze via fractography
9. Analyze via metallography
10. Determine cause of failure

4. Synthesize and summarize data; determine and report the root cause of failure
   
   
5. Case Histories
   1. On-site metallography of structural steel failure
   2. Failure analysis of conveyor drive shaft
   3. Metallurgical failure analysis of a welded hydraulic cylinder
   4. Aircraft component failure analysis
   5. Cap screw assembly failure
   6. Turbine blade failure investigation
   7. Corrosion failure analysis
   8. Turbine blade corrosion analysis
   9. Analysis of coating failures
   10. Bridge failure investigation
   11. FBE coating failure analysis
   12. Boiler tube failure analysis
   13. Construction failure case histories

About the Instructor
Mehrooz Zamanzadeh, Ph.D., FASM, FNACE, is a materials specialist with more than 25 years of practical experience in the fields of failure analysis and materials characterization. He earned his doctorate in materials science from The Pennsylvania State University. Dr. Zamanzadeh joined NIOC as a research fellow upon completion of his doctoral work in 1980. In 1985, he joined Carnegie Mellon University as a post doctoral research associate under a grant from IBM. Currently, he is president of Matco Associates.

Dr. Zamanzadeh holds four certifications from NACE International, including materials selection and design specialist; corrosion specialist; cathodic protection and coating specialist. He is one of the few awarded fellowship status from both NACE and ASM International for his outstanding contributions to the field of material science. Dr. Zamanzadeh has performed and reviewed thousands of failure analyses and has published many technical papers in various technical journals, books and associations. Additionally, he has 29 patents.