ASM Failure Analysis Case Histories: Design Flaws documents nearly 30 cases of structural and/or functional failure resulting from material selection errors, stress risers, mechanical resonance, inadequate material specifications, and sizing and configuration errors. The cases describe the investigation, identify the primary cause, and include remedial solutions. These case histories have been compiled from a wide variety of ASM International publication types, including ASM Handbook volumes, conference proceedings, technical books, journals, and magazines.

The compilation project involved reviewing hundreds of potential source publications to identify and select articles and chapters that address the investigation and analysis of specific component failures. The goal of compiling and organizing this content is to make it easier for failure analysts, design engineers, and other technical personnel to learn from the experience of others and to find information, examples, and methods that may be relevant to their own work.

Because these compiled case histories come from disparate sources published over several decades, they vary significantly in terms of the amount of detail provided, the tools and techniques utilized, and the conclusions and recommendations presented. All of the cases have been taken from credible, peer-reviewed sources, but no attempt has been made to certify that any given document reflects the current state of the art at the time of original collection and adaptation (2004-2005) or the organization of the present volume (2019). Despite these caveats, this collection is a treasure trove of examples and insights documented by failure analysts working at the highest levels of their profession.

This collection is possible because of broad-based involvement by members of ASM International who participate in the contribution and review of failure analysis information. In 2016, the Failure Analysis Society (FAS) was formed as an affiliate society of ASM International. The FAS is dedicated to advancing the important role failure analysis plays in the materials industry. The affiliate society emerged from a long-standing ASM Failure Analysis Committee that organized conference programs and provided oversight to ASM content activities, including the project that resulted in the publication of this compilation.

ASM International and the FAS continue to serve the failure analysis community through conference programming, education courses, and publications. Failure analysts are invited to submit new case histories and technical articles to the Journal of Failure Analysis and Prevention, the flagship publication of the FAS.