Failure Analysis: Identifying Causes, Improving Products

Failure Analysis (FA) refers to the process aimed at identifying and understanding the causes and mechanisms behind damage, anomalies, or deviations from the expected behavior of a component. These failures may occur during production or operational phases.

This analysis provides a fundamental contribution to the continuous improvement of production processes and the quality of the final product, particularly in competitive industrial environments that demand ever higher performance while reducing time and costs.

Over the last thirty years, Failure Analysis has developed into a true multidisciplinary science, involving fields such as metallurgy, chemistry, and mechanical engineering (both high and low temperature), to determine why a project failed to perform optimally under expected conditions of use.

Although a global standardization of FA practices has not yet been achieved—despite being often called for—Failure Analysis is generally conducted following a well-established and widely accepted sequence of operational steps, such as:

• Collection of relevant information (technical drawings, work sheets, usage history, operator testimonials, etc.)

• Macroscopic and microscopic visual inspection

• Non-destructive testing

• Fractographic analysis

• Material characterization and compliance checks with specifications

• Micrographic exams (purity check, weld joint inspection, detection of metallurgical anomalies, etc.)

• Review of design calculations (applied loads, component life, etc.)

• Special measurements if needed (e.g., residual stress)

• Simulations and testing under controlled conditions

• Statistical analysis of results

• Final report with interpretation and corrective/improvement recommendations

It’s important to note that each FA case is unique, depending on the specific features of the product and manufacturing process, as well as the combination of variables involved during production and use. As such, every investigation follows its own tailored path, often applying analytical methods that are not strictly standardized.

This is where Remet Controlli’s guiding principle comes into play:ANALYSIS, DIAGNOSIS, THERAPY

After a precise analysis of the data, FA must deliver an accurate diagnosis, clearly defining the causes of the failure and its mechanism.Finally, the therapy consists of recommending corrective actions, improvements, or even innovative changes to the product.

During the manufacturing or service life of a product, unexpected events may compromise its quality—for example, a surface that should be shiny may appear dull, corrosion may occur during storage or transportation, or a mechanical failure may happen due to overload. Other examples include seizure between moving parts or short circuits in electronic boards.

In all these cases, a scientific and accurate investigation of the underlying causes helps to first identify the nature of the defect and then define the corrective actions necessary to prevent recurrence, thereby improving product performance.

Proactively investigating such issues during the R&D phase is essential for product optimization and for enhancing quality and competitiveness. It helps achieve higher standards, build a strong reputation, and accumulate a valuable knowledge base. Moreover, it supports operational continuity, strengthens company culture, and fosters effective collaboration between departments involved in production.

Failure Analysis can also be conducted reactively—i.e., when issues arise unexpectedly during a product's lifecycle. However, this approach is slower, occasional, and does not always prevent negative consequences on cost, reliability, and safety. It is often limited to managing disputes.

For all these reasons, Failure Analysis is an essential tool. Partnering with a reliable laboratory for FA investigations—working together with mutual support toward product improvement—offers exceptional development potential and ensures timely, skilled responses to implement corrective actions and avoid future issues.

Collaborating with an experienced, well-integrated, and multidisciplinary team that actively engages with the customer during R&D allows for evaluating the contribution of different stages (design, material selection, manufacturing, finishing, assembly, storage, transport, and operational conditions) to the root causes of damage.

Ultimately, the cost of Failure Analysis is significantly lower than the cost of not identifying and addressing problems—such as returns, reputational damage, and chaotic last-minute fixes that may be ineffective. A targeted and well-planned FA approach results in cost savings and avoids serious consequences that could threaten the success of a business.

Integrating well-executed FA with other R&D activities—like finite element analysis, specification optimization, prototyping, and testing—enables the development of reliable, durable, and cost-effective products through a proactive approach.Working with trusted FA partners using rigorous, systematic, and interdisciplinary methods enhances product performance, extends lifecycle, ensures compliance with higher safety standards, optimizes costs, reduces disputes and liability, and boosts product reliability and brand credibility.

Contact us for more:📧 laboratorio@remet.it