Failure Analysis Training 11

[MaterialKat]

I'm looking to become the sole failure analysis materials engineer for my company. They have no training programs or previous engineers that can train me. I am looking for recommendation for the best books to have or training programs to attend. I haven't done any serious failure analysis for 8 years since the one class I took in college. We'll probably be dealing mostly with steel, but we are a job shop and also might have to deal with aluminum, copper, titanium, assemblies, and whatever they feel like asking for, so I want something or somethings that cover a wide range of materials. We have a full lab with light and SEM microscopes, hardness, various chemistry testers, etc, though most failure analysis I remember from college involved the microscopes primarily.

So far, I have the 2002 "ASM Handbook Volume 11: Failure Analysis and Prevention" and a couple old ASM conference proceeding books (though I hate the disjointed article format in those books).

I was looking at the ASM website and their list of training and books. Looking for reviews and recommendations.
I was thinking about getting the "Failure analysis of engineering structures: methodology and case histories" book, if it is useful enough knowing I already have the ASM Handbook Vol 11.
What I really need is a good reference book full of pictures for comparison and something that lists all the possible common causes for failure for certain applications.
Any recommendations would be appreciated.

 

[Maui]

Understanding How Components Fail by Donald J. Wulpi

http://www.amazon.com/Understanding-How-Components-Fail-06812G/dp/0871706318

Maui

http://www.EngineeringMetallurgy.com

 

[Goahead]

You may wish to see the ASM International Portal and then browse through the Education Tab > Self Study courses (page3)
for "Principles of Failure Analysis (7-Lesson Series)"
and also the tab of Failure analysis for courses or
the Store > Failure Analysis for books.

http://www.welding-advisers.com/

 

[weldstan]

In addition to the above, some Universities also have courses in Failure Analysis. You may wish to enroll if a University near you has one.

 

[TVP]

Kat,

I think that there are 3 categories of information on this subject:

1. training class
2. failure analysis books
3. case studies, compendia, etc.

For training classes, look at ASM website. These are excellent, and will give you hands-on training in the proper technique for using microscopes, etc.

For failure analysis books, the Wulpi book recommended by Maui is good. But ASM Volume 11 has more extensive coverage of all topics, so if your budget is tight, I would recommend spending your money in other areas like 1. or 3.

For case studies, the book that you mentioned is ok-to-good. However, I HIGHLY recommend the Handbook of Case Histories in Failure Analysis (Volumes 1 and 2), edited by Khlefa Esaklul. Excellent range of examples, extremely high quality of publishing, shorter articles that focus on linking test data to root cause of failure, rather than extensive description of background, test methods, etc. The book Failure Analysis of Heat Treated Steel Components is also excellent, but has a much narrower focus. There are also some very good technical papers, etc. freely available on the web. Use the following links for more information:

Handbook of Case Histories in Failure Analysis

http://www.amazon.com/Handbook-Histories-Failure-Analysis-Volume/dp/0871704536

Fractography of Metals and Plastics and other good articles

http://www.imrtest.com/get_technical_info/materials-testing-articles/index.html

An Introduction to Failure Analysis for Metallurgical Engineers

http://www.tms.org/Students/Winners/Davidson/Davidson.html

Numerous articles available here:

http://www.element.com/information/resources/articles-index

Other good resources:

http://ammtiac.alionscience.com/pdf/AMPQ9_1.pdf

http://ammtiac.alionscience.com/pdf/AMPQ9_2.pdf

http://ammtiac.alionscience.com/pdf/AMPQ9_3.pdf

http://www.accuratescrew.com/pdf/fastener_failures.pdf

http://www.sherrylabs.com/fasteners/access

http://www.matcoinc.com/home/technical-notes

 

[mrfailure]

You may want to consider actually taking the Principles of Failure Analysis course taught by an instructor through ASM. There is certain knowledge that is best imparted by having someone to talk with that imparts the texture of FA that books alone cannot do. Similarly, consider networking with other failure analysts (such as through the ASM Failure Analysis committee).

Aaron Tanzer

 

[racookpe1978]

I cannot tell you "how" to do this, but you need to develop a strong sense of "suspicion" and "skepticism" as well: an instinct almost of where the problem lies, and where people are trying to get you to direct the blame. Millions of dollars, Euro's, yen, and pounds are, after all, at stake.

For example: A 12 million dollar pressure vessel was damaged when it was lifted off of a barge unto a dock, delaying a 300 million dollar plant startup until a new pressure vessel could be built, shipped, and installed.

Case 1. The lifting shackle busted, dropping the PV.
Case 2. The vessel was lifted, but the lifting lug tore off at the weld.
Case 3. The shackle, lifting lug survived, but the vessel head was distorted during the l;ift.

Seems like three different root causes, three different results, right? Three different companies to blame perhaps - and pay all of the penalties to everybody else.
But the real cause was the same in all three "results" - the nbr 2 crane operator "jerked" the load up, accelerating it and creating out-of-design forces on that end of the PV.

 

[MaterialKat]

Thank you everyone for your recommendations. I will compile this list of books and training courses to submit to my manager, as well as check out those free references as well.

 

[Guest102023]

I don't want to dampen your enthusiasm but I believe it is a rare person who could learn failure analysis by self-teaching. The best thing that happened to me was having a mentor who schooled me in ALL aspects of investigations and report writing. It could work if you are only dealing with your own company's products, meaning you will see a narrow range of failures. You will also need access to a friendly met lab. The ASM course mentioned above is a good suggestion. Eng-tips is the best internet forum I have found, extremely helpful and troll-free.

p.s., if you make this a career, be prepared to absorb a ridiculous amount of knowledge and to never stop researching.

"If you don't have time to do the job right the first time, when are you going to find time to repair it?"

 

[Guest102023]

MKat,

I agree with you about the ASM failure analysis handbook, which I think is the green (current) one. The previous (red) edition had entire sections organized by industry type, such as boilers and refinery. I find that approach far more useful.

"If you don't have time to do the job right the first time, when are you going to find time to repair it?"

 

[mrfailure]

The two different types of organization are each useful in their own ways. We organized the current book so readers could get a thorough understanding of how failure mechanisms worked regardless of what industry they were seen in. The previous volume is extremely valuable with certain types of components where failure interactions are truly unique - I find the chapter on bearings to be particularly useful in this regard.