Failure analysis is an investigative process that uses visual observations of features present on a failed component fracture surface combined with component and environmental conditions to determine the root cause of a failure. The primary means of recording the conditions and features observed during a failure analysis investigation is photography. Failure analysis photographic imaging is a combination of both science and art; experience and proper imaging techniques are required to produce an accurate and meaningful fracture surface photograph. This article reviews photographic principles and techniques as applied to failure analysis, both in the field and in the laboratory. The discussion covers the processes involved in field and laboratory photographic documentations, provides a description of professional digital cameras, and gives information on photographic lighting and microscopic photography. Special techniques can be employed to deal with highly reflective conditions and are also described in this article.

Failure analysis is an investigative process in which the visual observations of features present on a failed component and the surrounding environment are essential in determining the root cause of a failure. This article reviews the basic photographic principles and techniques that are applied to failure analysis, both in the field and in the laboratory. It discusses the processes involved in visual examination, field photographic documentation, and laboratory photographic documentation of failed components. The article describes the operating principles of each part of a professional digital camera. It covers basic photographic principles and manipulation of settings that assist in producing high-quality images. The need for accurate photographic documentation in failure analysis is also presented.

This article reviews photographic principles, namely, visual examination, field photographic documentation, and laboratory photographic documentation, as applied to failure analysis and the specific techniques employed in both the field and laboratory. It provides information on the photographic equipment used in failure analysis and on film and digital photography. The article describes the basics of photography and the uses of different types of lighting in photography of a fractured surface. The article also addresses the techniques involved in macrophotography and microscopic photography as well as other special techniques.

Fractography is the systematic study of fractures and fracture surfaces. It is a useful tool in failure analysis and provides a means for correlating the influence of microstructure on the fracture mode of a given material. This article discusses the preservation, preparation, and photography of fractured parts and surfaces, and describes some of the more common fractographic features revealed by light microscopy, including tensile-fracture surface marks in unnotched specimens, fatigue marks, and structural discontinuities within the metal. The article also explains how to interpret fracture information contained in optical and scanning-electron microscope fractographs.

This article discusses the organization required at the outset of a failure investigation and provides a methodology with some organizational tools. It focuses on the use of problem-solving tools such as a fault tree analysis combined with critical thinking. The discussion covers nine steps to organize a good failure investigation. They are as follows: understand and negotiate goals of the investigation, obtain a clear understanding of the failure, identify all possible root causes, objectively evaluate the likelihood of each root cause, converge on the most likely root cause(s), objectively and clearly identify all possible corrective actions, objectively evaluate each corrective action, select optimal corrective action(s), and evaluate effectiveness of selected corrective action(s). Common problems detrimental to a failure investigation are also covered.

This article reviews the most common reasons for failures and the purpose of a failure investigation. It discusses the nine steps for the organization of a good failure investigation. The three basic tools that are helpful in any failure investigation, namely, a fault tree, a failure mode assessment chart, and a technical plan for resolution chart, are reviewed. The article briefly describes failure investigation pitfalls and concludes with information on the other common tools used for failure investigation and root cause determination.

Failure analysis is generally defined as the investigation and analysis of parts or structures that have failed or appeared to have failed to perform their intended duty. Methods of field inspection and initial examination are also critical factors for both reconstruction analysts and materials failure analysts. This article focuses on the general methods and approaches from the perspective of a reconstruction analyst. It describes the elements of accident reconstruction, which have conceptual similarity with the principles for failure analysis of material incidents that are less complex than a large-scale accident. The approach presented is that the analysis and reconstruction is based on the physical evidence. The article provides a brief review of some general concepts on the use and limitations of advanced data acquisition tools and computer modeling. Legal implications of destructive testing are discussed in detail.

Failure analysis is the process used to determine the cause of a failure. There is no definitive method for performing a failure analysis, and the method chosen is dependent upon the type of failure, the availability of background information, the tools available to perform the analysis, and the skills of the analyst. The information outlined in this article focuses on the general methodology while allowing for case-specific techniques to be utilized along the way. It covers the causes of failure, why a failure analysis is performed, the failure analysis process, the planning of failure analysis investigation, recommendations to prevent the need for a failure analysis, the implementation of product reviews, and forensic standards.

This article focuses on the aspects associated with inspection related to pressure vessels and pipework. These aspects include inspection policy, inspection planning and procedures, inspection strategy, inspection methodology, preparation for inspection, invasive inspection, internal visual inspection, and non-invasive inspection. Inspection execution, risk-based inspection, competence assurance of inspection personnel, inspection coverage, inspection periodicity, inspection anomaly criteria, assessment of fitness, and reporting requirements, are also discussed. The article addresses the data acquisition, reporting and trending, and review and audit for the inspection. It reviews inspection techniques, including visual inspection, ultrasonic inspection, and radiographic inspection.

This article outlines the basic steps to be followed and the range of techniques available for failure analysis, namely, background data assembling, visual examination, microfractography, chemical analysis, metallographic examination, electron microscopy, electron microprobe analysis, X-ray techniques, and simulations. It also describes the steps for analyzing the data, preparing the report, preservation of evidence, and follow-up on recommendations.

Additive manufacturing (AM) provides exceptional design flexibility, enabling the manufacture of parts with shapes and functions not viable with traditional manufacturing processes. The two paradigms aiming to leverage computational methods to design AM parts imbuing the design-for-additive-manufacturing (DFAM) principles are design optimization (DO) and simulation-driven design (SDD). In line with the adoption of AM processes by industry and extensive research efforts in the research community, this article focuses on powder-bed fusion for metal AM and material extrusion for polymer AM. It includes detailed sections on SDD and DO as well as three case studies on the adoption of SDD, DO, and artificial-intelligence-based DFAM in real-life engineering applications, highlighting the benefits of these methods for the wider adoption of AM in the manufacturing industry.