Forensic Engineering

KKKM6033
Synopsis of the course
This course focuses in
i the investigation of materials, products, structures or
components that fail or do not operate or function as
intended, causing personal injury or damage to property.
i This course provides in-depth graduate level foundation of
failure mechanisms and analysis.
Synopsis of the course
Students will study
i fracture mechanics,
i stress and strain,
i fatigue,
i creep and high temperature failures, and
i corrosion.
i Engineering case study based on actual failure
investigations will be discussed during the lectures.
i to analyse and interpret cause of failure of an engineering
structural component in terms of fundamental fracture
mechanics and failure analysis concepts.
Course Outcomes (CO)
Ability to describe the mechanisms of failure.
Ability to carry out flaw analysis in structural design and
safety assessments.
Ability to predict the performance and lifetime of structures
under severe conditions.
Ability to evaluate the root cause of failure of engineering
components and structures, and design solutions for
prevention of failure.
Ability to elaborate and defense ideas in project
presentation.
Schedule
Week Topic
1 Introduction to Forensic Engineering
2 Strength of solids
3 Types of fractures and failures
4 Stress concentration & fracture mechanics approach
5 Fracture criteria & fracture toughness
6 Fatigue failure
7 Case study 1
Cuti Pertengahan Semester
8 Mid sem exam & project assignment
9 Creep - High temperature failure
10 Corrosion & wear
11 Case study 2
12 Root cause determination & report writing
13 Forensic Engineering project
14 Project presentation
 Introduction
to Forensic Engineering
Watch your step!!!
Failure of Engineering
Structures
19 workers were killed in China
Statistics of no. of research
papers on failure analysis
What Is
Forensic Engineering?
i Forensic engineering is the
investigation of materials, products,
structures or components that fail or
do not operate or function as intended
(we called it failure), causing personal
injury or damage to property.
What Is
Forensic Engineering?
i Much more common in civil cases than
criminal cases.
i The purpose of a forensic engineering
investigation is to locate the cause or causes
of failure with a view to improve
performance or life of a component
Where are Forensic
Engineers Used?
i Most engineering disasters (building
collapses, out of design anomalies) are
subject to forensic investigation by
engineers experienced in forensic methods
of investigation.
i Train derailments, aircraft crashes and some
automobile accidents are investigated by
forensic engineers
Where are Forensic
Engineers Used?
i Consumer products, medical devices,
structures, industrial machinery, and even
basic tools can warrant investigations upon
incidents causing injury or property
damages.
i Insurance companies use forensic engineers
to prove liability or non liability
Why Failure Analysis
Is Important
What, Why and How of
Failure Analysis
Failure Analysis 57
What is Failure?
‘Definition of Failure'

o a device or structure is no longer able to

function as intended.

o system or part of a system fails to perform up

to the expectations for which it was created.

Failure Analysis 58
Failure
Failure is often the end result of unexpected
factors:

o Unforeseen vibrations develop;

o unanticipated temperatures are encountered;
o manufacturing tolerances can not be held;
o components do not quite mate as intended;
o the product is used or serviced in unintended
ways.

Failure Analysis 59
Failure is a human concept
Materials do not fail in and of themselves.

o They follow the laws of nature perfectly.

o If a part is loaded beyond its ‘tensile strength’,
it breaks.
o Until that stress level is reached, it does not
break.

Failure Analysis 60
When a part fails in service
o under-designed
o bad engineering
o poor manufacturing
o inadequate quality control
o fraud
o typographical errors

Failure Analysis 61
"Just because you can,
does not mean you should"

Failure Analysis 62
Failures Are Caused by
Human Errors

Three general types of error:

o Error of knowledge
o Error of performance
o Error of intent

Tidak boleh menyalahkan Tuhan atas kemalangan

yang berlaku:
- Ini kehendak Tuhan
- Ini takdir Ilahi…..

Failure Analysis 63
Error of knowledge
Involve insufficient knowledge, education,
training, and/or experience.

o Hydrogen Embrittlement (HE) causes

otherwise stable high strength steel
components to fail.

Failure Analysis 64
Error of performance
Result from lack of sufficient care or from
negligence. Negligence involves such things as
misreading of drawings, inadequate specifications,
and defective manufacturing and workmanship.

o Recent NASA failures in a Mars mission

involved the incorrect conversion from the
English to the Metric System of measurement
in a computer program.

Failure Analysis 65
Error of intent
Very commonly involve greed. Greed leads to
actions usually carried out with a conscious or
unconscious denial of full knowledge of the
potential consequences.

o Cost reduction driving design of military

vehicles causing premature failures.

o Aloha stadium superstructure corrosion

failures were caused by lack of surface
preparation and poor materials and coating
selection.

Failure Analysis 66
What is Failure Analysis?
'forensic engineering'

- the investigation of failed components with a

view to ascertaining the cause of failure in order
to prevent further failure, injury or loss of life,
and thus reduce any associated financial loss.

Failure Analysis 67
Why Undertake a Failure
Analysis?

Most important: To prevent future failures

Sometimes: To find who to be blamed

Failure Analysis 68
What Are Some of The
Effects of Failure?
o Loss of profit
o Injury
o Loss of life

o If a detailed failure analysis is carried out

and appropriate ameliorating action taken
repetition of such failure can often be
avoided.

Failure Analysis 69
What Are Some of The
Agents of Failure?
Four major failure agents

o Force
o Material
o Time
o Environment

This means that components will only fail due

to one, or perhaps a combination of several,
of these four failure agents.

Failure Analysis 70
What are Some of the Cause
of Failure of Machinery?
At least one or more of the following seven
cause categories:

o Faulty design
o Material defects
o Fabrication and/or processing error
o Assembly or installation defects
o Off-design or unintended service conditions
o Maintenance deficiencies, including neglect
and procedures
o Improper operation

Failure Analysis 71
Some Other Causes of
Failure
o Misuse or Abuse
o Manufacturing defects
o Improper maintenance
o Fastener failure
o Improper material
o Improper heat treatments
o Unforeseen operating conditions
o Inadequate quality assurance
o Inadequate environmental protection/control
o Casting discontinuities

Failure Analysis 72
What Can Be Done to
Prevent Failure?
An understanding of possible causes of failure,
allows the risk of premature failure to be
minimized.

o Kept acceptably low stress level

o Materials chosen are able to withstand
severe environment
o Quality control standards need to be imposed
o Manufactured components meet the the
requirement of the design
o System needs to be operated as designed,
without abuse or overload.
Failure Analysis 73
What Can Be Done to
Prevent Failure?
o If, using appropriate techniques, a potential
failure and its cause can be identified to
prevent complete/final failure may, in some
cases, be taken.

o In other cases, if accurate loading data is

available and the material properties are
known, the potential for catastrophic failure
may be assessed using fracture mechanics
principles, such as life prediction.

Failure Analysis 74
Important

Many failures are preventable if we

understand the materials and their intended
applications well enough and are willing to pay
the required costs for safety and durability.

Failure Analysis 75