A Re-Examination of Failure Analysis and Root Cause Determination

10SEMIntensLeft & Below: Line scanningisolates an area of the specimen.The red line indicates the locationof the scan.CC5000 200 400FeFeIntens2001501000 200 400IntensCr150100500 200 400Intens20CrNiNi0 200 4007. Confirm material composition and identify contaminants through EDS analysis.EDS (Energy-Dispersive Spectroscopy) is an analytical method based on thedifferences in energy of the characteristic x-rays emitted by the various elements. It isused in conjunction with scanning electron microscopy (SEM) to identify the elementspresent at a particular spot on a sample. Advantages of EDS are that it is easilyperformed and is reliable as a qualitative method. Limitations are that it is onlymarginally useful as a quantitative method.8. Analyze via Fractography, Fractography is used to determine the mode of fracture(intergranular, cleavage, or shear), the origin of fracture, and location and nature offlaws that may have initiated failure. With this information, the answer as to why a partfailed can usually be determined. The major use of fractography is to reveal therelationship between physical and mechanical processes involved in the fracturemechanism. The size of fracture characteristics range from gross features, easily seenwith the unaided eye, down to minute features just a few micrometers across.Light and electron microscopy are the two more common techniques used infractography. An important advantage of electron microscopy over conventional lightmicroscopy is that the depth of field in the SEM is much higher; thus the SEM can focuson all areas of a three-dimensional object identifying characteristic features such asstriations or inclusions.The texture of a fracture surface, that is, the roughness and the color, gives a goodindication of the interactions between the fracture path and the microstructure of thealloy. For instance, at low stress a fatigue fracture is typically silky and smooth inappearance. Stress corrosion fractures show extensive corrosion features and corrosion“beach marks.” A discontinuous ductile fracture shows some stages of crack tipblunting, crack arrest and "pop-in".9. Analyze via Metallography. Prepare a laboratory specimen with care not to removeinclusions, erode grain boundaries or compromise the sample in some other way. Studystructural characteristics in relation to its physical and mechanical properties at low and