A ReExamination of Failure Analysis and Root （失效分析和根的复审）.pdf

A Re-Examination of Failure Analysis and Root Cause Determination M. Zamanzadeh, E. Larkin and D. Gibbon Matco Associates PO Box 15580 Pittsburgh, Pennsylvania 15244 412-788-1263 December 2004 Failure analysis is a complex process applied to all different types of materials. Each class of materials requires special skills and experience to effectively unravel the causes of failure. This is the first in a series of papers focusing on these various subsets of materials. The series will include failures in metallurgy, paints and coatings, plastics and electronics, as well as failure caused by corrosion. Each paper in the series will also include an examination the principles of root cause determination within that particular field. This first paper is primarily concerned with the overall approach to failure analysis and with the applications of that approach to metallurgical failures. 2 TABLE OF CONTENTS Part 1: FAILURE ANALYSIS – A CONCEPTUAL FRAMEWORK I. Introduction Failures Are Caused by Human Errors Product Specifications and Failure Root-Cause Determination Defined V. How to Conduct a Failure Analysis Determine when, where and how the failure occurred Collect samples for laboratory examination Take on-site photographs Visually examine the sample Identify defects Non-Destructively Conduct appropriate chemical analyses Confirm material composition and identify contaminants through EDS analysis Analyze via Fractography Analyze via Metallography Determine the cause of failure Physical Testing Finite Ele