Introduction to

Failure Analyses
Dr. Ir. Winarto, M.Sc.

Departem en Metalurgi
Fakultas Teknik Universitas Indonesia

ANALISA KERUSAKAN (FA)

1
 ANALISA KERUSAKAN (FA)

Failure analysis : Why and Whom?

Service failures of components and structures:
experienced in several industries
+

often without any warning

+

 5 Service Failures may result in :

 Fatalities
 Injuries to personnel
 Damage to property
 Shutdown of an entire plant, Ecological problems such as
release of hazardous material
 Loss of production
 Expensive and prolonged litigations affecting the credibility of
the manufacturers and the reliability of their products

ANALISA KERUSAKAN (FA)

FAILURE ANALYSIS ?
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.

2
 ANALISA KERUSAKAN (FA)

OBJECTIVE OF A FAILURE ANALYSIS

A failure investigation and

subsequent analysis should determine the primary
cause of failure and, based on that determination,
alternative/recommend action to prevent or
minimize similar failures

ANALISA KERUSAKAN (FA)

20cm-crack

20cm-crack

3
 ANALISA KERUSAKAN (FA)

FAILURE CONDITIONS
 General Condition:
1. The 1st considered is a loss of function. A jet
engine that runs but can only produce partial
thrust (insufficient to enable an aircraft to take
off) is an example of a loss of function.
2. The next level of failure involves a system or
component that performs its function but is
unreliable or unsafe. a wire rope for an elevator
has lost its service life
3. In the next level of severity of failure, a system or
component is inoperable

ANALISA KERUSAKAN (FA)

Common causes of failures:

 Misuse (improperly operating condition)
 Assembly errors and improper maintenance
 Design errors,
 Manufacturing defects
 Improper materials selection
 Improper heat treatments
 Unforeseen operating conditions
 Inadequate environmental protection/control or High
temperature surface degradation processes

4
 ANALISA KERUSAKAN (FA)

Common causes of failures:

ANALISA KERUSAKAN (FA)

Failure analysis rules

 The failure investigator has only one ob jecti ve to determine the failure mechanism that
caused the failure and to use that knowledge to prevent another occurrence.

 Start with and maintain an open mind. Emotion obscures objectivity and must be ed ged
from the investigation.

 The theory, however elegant, must agree with the observed evidence, howe ver humble.

 The simplest solution is the best solution.

 Having the wrong solution is frequently much worse than having no solution.

 Major incidents are often triggered by very min or or apparently innocuous details.

 Only one thing is worse than knowing you have a crack growing in a component, and that
is not knowing you have a crack growing in a comp onent.

 Cracks never get smaller, nor do they ever disappear. Either they stay the same size
(invariably in a minor, insignifican t, or easil y repaired component), or they get bigger
(usually in a critical component).

5
 ANALISA KERUSAKAN (FA)

EQUATION FOR SUCCESSFUL FAILURE

ANALYSIS
Proper background information
+
correct analyses and tests
+
Thorough knowledge of materials behaviour
and processing
+
Pertinent experience
_________________________
Correct Analysis

ANALISA KERUSAKAN (FA)

Tools Used in Root Cause Analysis

6
 ANALISA KERUSAKAN (FA)

Fishbone Diagram - A Useful Tool

 Using a fishbone diagram while brainstorming
possible causes helps you to focus on the
various possibilities. Some useful categories:

ANALISA KERUSAKAN (FA)

FREQUENCY OF CAUSES OF FAILURE IN SOME

E NGINEEIRNG INDUSTRY INVESTIGATIONS

7
ANALISA KERUSAKAN (FA)

ANALISA KERUSAKAN (FA)

Where is the failure

location on a shoe?

Give a logical explanation

regarding with this failure!

- Where is the location?

- What is the cause?
- Give a conclusion
- Give recommendation.

8
 ANALISA KERUSAKAN (FA)

ANALISA KERUSAKAN (FA)

Conclusion
 Failure Analysis  Complex subject, and it is
covering with some items:
1. Physics, Chem., Metallrgy, Electro-Chem.
2. Manufacturing Processes
3. Stress analysis, Design Analysis
4. Fracture Mechanics, etc

 “To be expertiest FA”  “individually near

impossible”, hence it is required a “Team of
Experts”

9
 ANALISA KERUSAKAN (FA)

Home Works

1. Explain what is the definition of “failure” and

“Failure Analysis” in general!
2. What is the condition that the components is
said to be failure.
3. Mention the common cause of failure in
engineering materials.!
4. Please make the failure analysis on your “wrist
watch” to be used daily.
5. What can you derive from the knowledge of the
materials engineering failures ?

10