Course Catalogue.

After participating in this course, you will be able to:

• Analyse failed parts and components systematically and obtain conclusions based on sound scientific principles.
• Apply this information to improve the design and reliability of metallic, ceramic and polymer parts and machinery.

Description

Today’s competitive industrial environment demands reliable and effective solutions to problems. Root cause failure analysis is essential to improve quality and reliability and prevent catastrophic failures. While an extensive range of analytical techniques is available, proper methodology and techniques must be used to obtain reliable results.

This course will focus on practical techniques to perform successful failure analysis. Relying on years of experience, the instructor will describe techniques and approaches combined with practical examples. The participants are encouraged to bring examples from their experiences for discussion and preliminary analysis.

Who Should Attend

Plant Managers • Superintendents and Supervisors • Technical Managers • Engineering Consultants • Maintenance Personnel • Laboratory Personnel • Quality Management Personnel • Accident Investigators • Insurance Litigators and Purchase Officials

Course Syllabus

Day 1

Conducting A Successful Failure Analysis

Scientific method, Proper documentation and preservation of the evidence, Preliminary examination, Collection of data and samples, Photography and videos

Review of Basic Types of Materials

• Polymers, ceramics and alloys
• Mechanical and chemical properties

Types of Failures

• Ductile/Brittle, Fatigue, Wear
• High-temperature effects
• Cracking (hydrogen, scc)
• Corrosion

Corrosion Aspects

• Basic theory: Corrosion reactions, key parameters,
• eH –pH diagrams, kinetics, corrosion control
• Protection methods: coating, inhibitors, cathodic protection, material selection

Day 2

Analytical Tools

• Visual exams, Destructive vs non-destructive, Metallographies, Electron microscopy, FTIR, Chemical analysis (quantitative vs qualitative)

Practical Examples to Illustrate the Various Types and Causes of Failures:

• Typical material defects
• Material selection
• Fatigue
• Corrosion
• Welding
• Design vs manufacturing

Typical Examples of Failures in HVAC and Plumbing, Civil Engineering, Pressure Vessels, Extractive Metallurgy, Oil and Gas industry

Discussion of Examples (Participants are Encouraged to Present Examples for Group Discussion and Analysis)