Engineering failure analysis is the step-based approach to discovering the reason behind a breakdown in a part, system, or material. These breakdowns are usually linked to material issues or external factors. Specialists use technical assessments to examine what failed, when it failed, and why, in order to prevent similar issues from reoccurring.
Understanding Technical Investigations
An investigation aims to review failure mechanisms under specific loads, settings, or environments. It is used across sectors including energy, infrastructure, and transport. Investigators collect measurements, inspect the failed parts, and examine the data in context with design expectations. This approach enables fact-based reporting that can support future engineering decisions.
How Failure Is Investigated in Engineering
- Compile background information such as performance logs and installation records
- Inspect the component visually to find wear patterns, cracks, or misalignment
- Examine the microstructure using tools such as SEM or optical scopes
- Perform hardness checks and compositional assessments
- Match test outcomes with the expected load path and material limits
- Write a report detailing findings and improvement suggestions
engineering failure analysis
Industry Areas Benefiting from Failure Analysis
Failure reviews are carried out in sectors such as aerospace, nuclear, automotive, and rail. For example, a fractured pipe may require fracture surface analysis, or a collapsed beam may need calculations based on loading conditions. The analysis doesn’t only guide repair—it often leads to updates in material use that reduce cost and improve safety.
How Failure Analysis Supports Operations
These investigations minimise the risk of future faults, strengthen health and safety records, and contribute to better engineering decisions. They also support compliance with standards and provide defensible reports useful in claims or audits. Most importantly, they allow engineering teams to refine procedures based on real-world data.
Frequently Asked Questions
Why do faults get investigated?
Triggered by breakdowns, performance loss, or unexpected behaviour.
Who performs the work?
Typically, a combination of lab technicians and engineering consultants.
Which instruments are used?
Microscopes, spectrometers, modelling software, and force measurement tools may be used.
How long does a typical case take?
The duration depends on how complex the failure is. It could take a few days or a few weeks.
What happens after analysis is complete?
Evidence-based reporting, useful for technical teams, insurers, and legal review.
Closing Notes
This process supports safer systems, clearer technical understanding, and better engineering outcomes.
Visit GBB’s site to learn more about professional engineering investigations.