Root Cause Failure Analysis Services
When a critical component fails—whether it is an aerospace composite panel, a medical ceramic implant, or a polymer seal—it is more than a simple break. It is a sign of a systemic issue.
Our materials failure analysis service acts as a forensic investigation. We systematically dismantle the problem to look beyond the immediate damage, interrogating the material’s entire lifecycle: material selection, manufacturing processes, design applications, and environmental exposure.
Failure Modes by Material Type
Different materials require completely different analytical approaches. Our multidisciplinary team of chemists, engineers, and lab technicians matches the specific failure signs to the correct testing methods.
| Material Type | Common Signs of Failure | Primary Root Causes |
|---|---|---|
| Polymers | Cracking, premature aging, degradation | Incorrect material selection, unexpected chemical interactions |
| Composites | Micro-cracks, broken fibers, delamination | Excessive mechanical stress, overestimated load capacity, manufacturing defects |
| Coatings | Delamination, cracking, surface erosion | Substrate incompatibility, poor surface adhesion |
| Metals | Cracking, fracturing, deformation, surface wear | Material fatigue, corrosion, stress exceeding design limits |
| Welds | Cracking, porosity, lack of fusion | Poor welding technique, inadequate filler materials, improper joint preparation |
| Ceramics | Fractographic stresses, structural porosity, shattering | Thermal shock, environmental exposure, brittle fracturing |
Our Failure Analysis Laboratory & Methods
Once the visible signs of failure are documented, our laboratory replicates the component's operational environment to simulate failures in real-time. We utilize a comprehensive suite of advanced testing techniques:
- Microscopy & Fractography: Examining fracture surfaces at high magnification to pinpoint the exact origin and direction of a crack.
- Chemical Analysis: Verifying that the material composition matches specifications and identifying unexpected contaminants.
- Mechanical & Physical Testing: Evaluating tensile strength, hardness, fatigue life, and thermal properties for both metals and polymers.
Why Partner with IMR Test Labs?
We don't just hand you raw data; we deliver actionable knowledge to prevent future liability and downtime. Our final reports provide the concrete insights you need to modify designs, adjust manufacturing steps, or select alternative materials for maximum performance.
- Multidisciplinary Expertise: An expert team of chemists, technicians, and forensic engineers working on your case.
- State-of-the-Art Equipment: Access to advanced diagnostic tools capable of deep-dive material characterization.
- End-to-End Consultation: From initial intake and testing to final structural recommendations and engineering consultations.
Failure Analysis FAQs
IMR Test Labs evaluates a wide range of materials, including metals, polymers, composites, ceramics, and coatings. Our expertise encompasses assessing welds and finished products across various industries.
Our process includes visual examination, non-destructive testing, metallurgical analysis, mechanical testing, and chemical analysis. We employ advanced techniques to thoroughly investigate the failure and provide detailed insights.
The duration of the failure investigation varies based on the complexity of the failure and the specific analyses required. IMR Test Labs strive to deliver timely results with without compromising quality. For a precise timeline, please contact us with the details of your case.
Industries such as aerospace, automotive, energy, medical devices, and manufacturing benefit from our failure analysis services to ensure safety, reliability, and compliance with industry standards.
Yes, beyond identifying root cause, we provide recommendations for design improvements, material selection, and process enhancements to mitigate the risk of future failures. For more information or to discuss your specific needs, please contact us.
LITIGATION FAILURE ANALYSIS
Litigation and insurance claims need support from competent materials testing experts to reach the appropriate conclusions. Our labs in Ithaca, NY and Louisville, KY provide litigation support to clients in a wide range of industries. Clients rely on IMR to provide the following professional services:
- Trial Expert Witness Testimony
- Technical Disposition
- Legal Consultation
- Test Witness Services
FAILURE ANALYSIS TESTING PROCESSES
- Reviewing the steps that occured before the failure
- Simulating the conditions under which the failure occured
- Collecting samples for chemical analysis
- Investigating why some components, if any, remain intact
- Determining the root cause behind the failure
- Recommending steps to avoid future recurrence
In some circumstances, it aids the failure analysis process to inspect the site where the failures took place. Analyzing failures often involves multi-disciplinary processes. These can include the following:
- Chemical analysis through the use of various spectroscopy techniques
- Environmental exposure testing that approximates the operating conditions at the time of the failure's occurence
- Fractography, or the study of the fractured material surfaces
- Microscopic examination using scanning electron microscopes and similar equipment
- Mechanical testing utilizing a wide range of analytical equipment, and taking into account component geometry and failure parameters
FAILURE ANALYSIS TESTING SERVICES
IMR Test Labs offers a comprehensive array of failure analysis services for non-metallic materials, including the following:
- Fractography services, which are particularly useful for determining causes of fractures in plastic components and other non-metallic material surfaces.
- Investigative chemistry, including adhesive identification, coating contamination, contaminant identification, paint identification, and surface contamination. These are useful for analyzing paint adhesion failures and determining the presence of contaminants in paints and plastics.
- Physical testing for benchmarking plastic part materials and determining distribution of fibers in fiber-reinforced plastics, among others.
- Residual analysis, such as FTIR, scanning electron microscopy and energy dispersive X-ray analysis (there is a close relationship between investigative chemistry and residual analysis) for contaminant identification.
- Thermal analysis for measuring properties such as melting point, crystallization temperature, filler content and mechanical properties as a function of temperature.
- Litigation failure analysis, involving trial expert witness testimony, technical disposition, legal consultation, and test witness services.
The above services are available for a wide range of materials and parts, including electrical components, fabrics, medical tools and devices, plated parts, plastics, and printed circuit boards.
POLYMER / COMPOSITE FAILURE ANALYSIS SERVICES
Failure analysis of non-metallic materials is necessary to prevent the future recurrence of failures in non-metallic materials. There are different kinds of non-metallic failure analysis techniques. The use of these techniques ultimately depends on the type of non-metallic material to be analyzed and tested.
Request a quote to know more about our non-metallic failure analysis services.
Paints & Coatings
Coating Shear Fatigue
Coating Thickness
Dime Scrape
Flexibility
Impact Resistance
Material Identification (Base Polymer)
Material Properties of Liquid Paints and Coatings
MIL-STD-801 Section 504 Testing (Contamination by Fluids)
Pencil Hardness
Solvent Resistance
Specular Glass (20° and 60°)
Stain Resistance
Failure Analysis
Failure Mechanism
Root Cause
Applied Stresses
Fracture Origin
Trace Contaminants
Material Characterization
Additive Analysis to Trace Level
Bond Strength
Chemical Exposure Testing
Coefficient of Friction
Compression Set
Compressive Properties (-40°F to 660°F)
Density & Specific Gravity
DSC Analysis: Melting Point Glass Transition % Crystallinity
Dynamic Mechanical Analyzer (DMA) Testing
Extractables
Fatigue Testing (ambient temperature)
Flammability
Flexural Properties (-40°F to 660°F)
FTIR Analysis
Hardness (Rockwell, Durometer, Barcol)
Trace Analysis
Polymer Additives
Plasticizers
Leachable Compounds
Extractable Compounds
Semi-Volatile Compounds
Contaminants
Corrodents
XRD Analysis
Identification of Unkown Powders
Analysis of Corrosion Products
Phase Identification
Crystal Structure
Reverse Engineering
Competitive Analysis
Material Confirmation
Material Characterization
Hardness (Rockwell, Durometer, Barcol)
Heat Aging
Impact Strength
Lap Shear Testing
Material Identification
Melt Flow Rate/Index
SEM/EDS Analysis: Fillers
Tensile Properties (-40°F to 660°F)
TGA Analysis: Polymer Glass and Ash Content
TMA: Glass Transition, Coefficient of Thermal Expansion, Heat Deflection Viscosity
RELEVANT ACCREDITATIONS
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