Methodologies for failure analysis: a critical survey

Based on a critical survey of relevant literature, and own experience, a failure analysis methodology is presented, focusing on fracture and fatigue problems. Failures investigated by the authors include brittle fracture and fatigue of structures and machine elements, such as transportation equipment, structural connections, engines, etc. Further to their economic significance, some of the failures were of special concern because of safety, environmental or legal considerations. Difficulties for carrying out the analyses included circumstances not entirely known or documented, damaged fracture surfaces, or insufficient material to carry out comprehensive mechanical testing. Further to the detailed study of the available evidence, stress analyses using numerical methods such as the finite element or the boundary element methods, materials testing and scanning electron microscopy have been used as required. Suggestions for R&D efforts in the field are put forward.