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Failure analysis

Investigate the root cause of your equipment failure

What is failure analysis?

Failure analysis is a comprehensive investigation to determine failure mechanisms and root causes in the event of a breakdown. The root cause analysis procedure involves collecting and analysing data, developing appropriate corrective and/or preventive action, presenting the data clearly and generating a practical recommendation.

Why is failure analysis important?

Failure analysis detects the root cause of the failure mechanism and recommends preventive measures to avoid repeat occurrences. Regardless of whether you are a manufacturer or an operator, failures that contribute to downtime can affect your business operations and profitability. In worst-case scenarios, failures may even pose a risk to employees, the public and the environment, possibly resulting in reputational damage and lawsuits.

TÜV SÜD helps to prevent recurring failures and reduce costs from unexpected shutdowns.

TÜV SÜD’s leverages on its expertise in materials science and engineering, mechanical calculation, construction, process and system engineering, metallographic and chemical investigations, and electronics / biochemical / electrical / acoustic / surface analyses in providing failure analysis services. We offer statements on the root cause of failure for rehabilitation, repair, prevention of future failure. 

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What doES failure analysis involve?

  • Failure analysis

    In addition to determining the mechanism(s) and root cause(s) of the failure, we also recommend preventive measures to prevent recurrence of the failure and provide technical support in dispute cases, including expert testimony in court.

  • Materials-related evaluation

    TÜV SÜD offers materials expertise covering materials selection, evaluation on conditions of important devices, comparison of different processes, corrosion evaluation and protection, and weld quality evaluation. Our experts also provide risk assessment for special failure mechanisms such as hydrogen embrittlement, stress corrosion cracking, pitting corrosion and degradation of polymeric materials.

  • Troubleshooting

    We provide troubleshooting services for industrial processes such as:

  • Plating processes
  • Heat treatment processes 
  • Injection moulding processes 
  • Casting, forging and stamping processes 
  • Soldering, brazing and welding processes 
  • Assembling processes 
  • EDM processes
  • Evaluation (Metallurgical and Mechanical-Technological)

    Our evaluation services include metallurgical tests such as PCB cross-sectional examination, SEM/ EDX examination on coatings, metallographic examination, particle size distribution testing, X-ray radiography, X-ray CT, airworthiness welding qualification testing (AWQT) and over-temperature testing for aerospace (HPT, HPC blades). We also provide mechanical-technological tests such as tensile tests, bending tests, impact tests and hardness tests.

  • Training

    TÜV SÜD offers training courses for failure analysis as well as corrosion engineering. Our experts also provide guest lectures on failure analysis at universities.

  • Investigated components and structures

  • Power generation and supply: gas & steam turbine components, boilers, generator rotor shafts, boiler/waste heat boiler components, eco-components, electricity distribution station equipment, transformers, submarine power cables, switch gears, contactors, etc.
  • Renewable energy: assembly group & components such as solar assembly, wind turbine main bearing & gearbox bearing, etc.
  • Oil & gas: drilling equipment, offshore rigs, oil tankers, etc.
  • Petrochemical: high-T & high-P devices, tanks, pipes, heat exchangers, etc.
  • Real estate and infrastructure: crane booms, lifts, cable car systems, piling machines, tempered glass, panels, gas/water pipes, etc. 
  • Rail: rails, conduction rail system, OCS system, power cables, message cables, train structure, etc.
  • Aerospace: various aircraft engines, landing gear, engine starters, exhaust nozzles, engine mounts, helicopters, etc.
  • Marine: various submarines/ships, hovercraft engines, propellers, gearboxes, port structures and equipment, ship-lifting systems, offshore structures, etc.
  • Medical: stainless steel guide wire for heart operation, laryngeal mask, surgical implant, etc.
  • Electronics: IC chips, MLC, Ta-capacitor, PCBA, wafers, thermal printers, etc. 

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