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Failure Analysis Services

Root Cause Analysis, Failure Mode Determination


Our Procedure

At FAI Materials Testing Laboratory, our team of skilled failure analysis experts conduct in-depth investigations to determine the root cause of part and assembly failures and identify means for preventing future failures.  Working quickly and thoroughly with our analytical equipment, materials


After over a decade of conducting failure analysis investigations we've seen failed components and products from every industry. We have the experience and resources to solve your toughest problems.


characterization techniques, and decades of experience across multiple industries, FAI's failure analysts provide clear answers that ultimately deliver bottom-line results.  After over a decade of conducting failure analysis investigations we've seen failed components and products from every industry.  We have the experience and resources to solve your toughest problems. Our professional staff will conduct both on-site investigations and laboratory tests as part of our failure analysis service.  Since some failure analysis investigations involve legal issues, we also offer expert scientific witness services.


Learn More

You can read about our analytical testing techniques and equipment that we utilize in failure analysis investigations on our Techniques Page.  We also encourage you to check out our blog posts below about previous failure analysis investigations.



Failure Analysis Case Studies

Corrosion Study for Hospital

Cross-section of a copper pipe with sealant and corrosion

FAI Materials Testing Laboratory supported a construction company as they investigated corrosion on pipes throughout a new hospital. We conducted an on-site evaluation and worked with consultants from the hospital and the caulk manufacturer to reach a conclusion.

 

The cause of corrosion was a water-based acoustical sealant. After analysis of the water-based sealant using Headspace GC-MS, extensive optical and metallographic microscopy to study the extent of the corrosion, and ion chromatography to quantify the corrosive agent, FAI determined that the pipes needed to be replaced and tested a new silicone-based caulk for replacement. This was all completed on schedule and the construction company was able to perform an emergency replacement of all pipes in the building to stay on track for the grand opening.


Plastic Bottle Anomalies

Phthalate crystallized on a layer of polyester from a rejected bottle

A worldwide plastic bottle manufacturer was experiencing rejections on their manufacturing line. Bottles were coming off of the line with hazy or translucent areas/spots. They contacted FAI Materials Testing Laboratory to solve the problem.

Using a combination of optical and electron microscopy, Fourier transform infrared (FT-IR) spectroscopy, and energy dispersive x-ray spectroscopy, FAI determined the cause of rejection to be insufficient mixing of a phthalate (a plastic additive that adds flexibility) with the rest of the polyester base material. The unmixed phthalate crystallized later in the manufacturing process, causing hazy areas on the bottle. The bottle manufacturer was able to make quick adjustments to their equipment and avoided a major factory shutdown.



What is Failure Analysis?


Call us at 770-928-1930 orcontact us to see how we can help you today.