Contents: v 1. Properties and selection--irons, steels, and high-performance alloys--v 2. Properties and selection---nonferrous alloys and special-purpose materials[etc ]v 21 Composites 1. Metals--Handbooks. manuals. etc. 2. Metal-work--Handbooks manuals. etc. L. ASM International Handbook Committee. IL Metals Handbook TA459M431990620.1690-115 SAN:204-7586 ISBN:0-87170-704 ASM International Materials Park, OH 44073-0002 www.asminternational.org Printed in the United States of America Multiple copy reprints of individual articles are available from Technical Department, ASM International Introduction to Failure Analysis and prevention James J. Scutti, Massachusetts Materials Research, Inc; William J McBrine, ALTRAN Corporation Introduction ANALYZING FAILURES is a critical process in determining the physical root causes of problems. The process is complex, draws upon many different technical disciplines, and uses a variety of observation, inspection, and laboratory techniques. One of the key factors in properly performing a failure analysis is keeping an open mind while examining and analyzing the evidence to foster a clear, unbiased perspective of the failure. Collaboration with experts in other disciplines is required in certain circumstances to integrate the analysis of the evidence with a quantitative understanding of the stressors and background information on the design, manufacture, and service history of the failed product or system Just as failure analysis is a proven discipline for identifying the physical roots of failures, root-cause analysis(RCa) techniques are effective in exploring some of the other contributors to failures, such as the human and latent root causes Properly performed, failure analysis and RCA are critical steps in the overall problem-solving process and are key ingredients for correcting and preventing failures, achieving higher levels of quality and reliability, and ultimately enhancing customer satisfaction This article briefly introduces the concepts of failure analysis, root-cause analysis, and the role of failure analysis as a general engineering tool for enhancing product quality and failure prevention. The discipline of failure analysis has evolved and matured, as it has been employed and formalized as a means for failure prevention. Consistent with the ent trend toward increased accountability and responsibility, its purpose has been extended to include determining which party may be liable for losses, be they loss of production, property damage, injury, or fatality. The discipline has also been used effectively as a teaching tool for new or less experienced engineers The importance and value of failure analysis to safety, reliability, performance, and economy are well documented. For ample, the importance of investigating failures is vividly illustrated in the pioneering efforts of the Wright Brothers in developing self-propelled flight. In fact, while Wilbur was traveling in France in 1908, Orville was conducting flight tests for the U.S. Army Signal Corps and was injured when his Wright Flyer crashed(Fig. 1). His passenger sustained fatal injuries(Ref 1). Upon receiving word of the mishap, Wilbur immediately ordered the delivery of the failed flyer to france so that he could conduct a thorough investigation. This was decades before the formal discipline called"failure analysis was introduced Thefileisdownloadedfromwww.bzfxw.comContents: v.1. Properties and selection—irons, steels, and high-performance alloys—v.2. Properties and selection—nonferrous alloys and special-purpose materials—[etc.]—v.21. Composites 1. Metals—Handbooks, manuals, etc. 2. Metal-work—Handbooks, manuals, etc. I. ASM International. Handbook Committee. II. Metals Handbook. TA459.M43 1990 620.1′6 90-115 SAN: 204-7586 ISBN: 0-87170-704-7 ASM International Materials Park, OH 44073-0002 www.asminternational.org Printed in the United States of America Multiple copy reprints of individual articles are available from Technical Department, ASM International. Introduction to Failure Analysis and Prevention James J. Scutti, Massachusetts Materials Research, Inc.; William J. McBrine, ALTRAN Corporation Introduction ANALYZING FAILURES is a critical process in determining the physical root causes of problems. The process is complex, draws upon many different technical disciplines, and uses a variety of observation, inspection, and laboratory techniques. One of the key factors in properly performing a failure analysis is keeping an open mind while examining and analyzing the evidence to foster a clear, unbiased perspective of the failure. Collaboration with experts in other disciplines is required in certain circumstances to integrate the analysis of the evidence with a quantitative understanding of the stressors and background information on the design, manufacture, and service history of the failed product or system. Just as failure analysis is a proven discipline for identifying the physical roots of failures, root-cause analysis (RCA) techniques are effective in exploring some of the other contributors to failures, such as the human and latent root causes. Properly performed, failure analysis and RCA are critical steps in the overall problem-solving process and are key ingredients for correcting and preventing failures, achieving higher levels of quality and reliability, and ultimately enhancing customer satisfaction. This article briefly introduces the concepts of failure analysis, root-cause analysis, and the role of failure analysis as a general engineering tool for enhancing product quality and failure prevention. The discipline of failure analysis has evolved and matured, as it has been employed and formalized as a means for failure prevention. Consistent with the recent trend toward increased accountability and responsibility, its purpose has been extended to include determining which party may be liable for losses, be they loss of production, property damage, injury, or fatality. The discipline has also been used effectively as a teaching tool for new or less experienced engineers. The importance and value of failure analysis to safety, reliability, performance, and economy are well documented. For example, the importance of investigating failures is vividly illustrated in the pioneering efforts of the Wright Brothers in developing self-propelled flight. In fact, while Wilbur was traveling in France in 1908, Orville was conducting flight tests for the U.S. Army Signal Corps and was injured when his Wright Flyer crashed (Fig. 1). His passenger sustained fatal injuries (Ref 1). Upon receiving word of the mishap, Wilbur immediately ordered the delivery of the failed flyer to France so that he could conduct a thorough investigation. This was decades before the formal discipline called “failure analysis” was introduced. The file is downloaded from www.bzfxw.com