What are the key steps and tools for conducting a forensic failure analysis of a product or component?

Proper handling and storage of failed samples prevent contamination and tempering of evidence which could compromise the accuracy of the failure analysis. Contamination can occur from environmental factors, handling by unauthorized individuals, or improper storage conditions. By preserving evidence in its original state, forensic analysts can accurately identify the root causes of failure as well as it can be confidently presented in legal proceedings as proof of liability or innocence. It provides a solid foundation for expert testimony and strengthens the case's credibility in court.

Visual inspection of failed part involves documenting the as-recieved condition of the failed component through high resolution digital photographs, schematic sketches, or written descriptions of sequence of events. This documentation might serve as valuable evidence for further analysis and could be used to support findings in reports or legal proceedings. Visual inspection allows analysts to assess the material properties (and external factors) of the failed component, such as texture, color, surface finish, improper installation, operational misuse, or environmental conditions as well as presence of surface anomalies. These observations can provide insights into the material's condition, quality, and potential manufacturing defects.

Please make sure to do NDT only if it is required. If the damage in the failed part is due to corrosion then I would suggest not to conduct any NDT at the damage area otherwise the elemental chemistry of the deposits and other evidence will be Contaminated and root cause may be compromised.

Destructive testing like mechanical testing of the failed part is primarily done to check if the failed component meets the materials properties as per material specification or grade. If the manufacturing test mill certificate values are not in line with the mechanical test values which failure analyst get on failed part then it is improper material slipped into the assembly. Similarly mechanical properties by destructive testing like hardness values helps to do the structure property corelation in understanding the correctness of the heat treatment of the material.

Analysis of lab test results aids in identifying the root cause of failure by pinpointing the factors or conditions that contributed to the observed behavior of the failed part. This may involve correlating material properties, design features, manufacturing processes, or external influences with failure outcomes. Analyzing lab test data and test results is a critical step in forensic failure analysis, which provide the empirical basis for understanding failure or damage mechanisms, identifying root causes, and recommending preventive measures.

This being a viral step, it is important to take care of following points; 1)Clearly defined failure statement including background.It should at the least include reference numbers of the failed system (e.g. engine/compressor/excavator/aeroplane/any other equipment), the number of hours of service at the time of failure, scheduled maintenance work carried out on the failed system before failure, date & time of the failure & anything which might be of importance. 2)Observations should be reported in non-conclusive manner backed up with photos. 3)Hypotheses of the failure mode based on interpretations from the observations to be included 4)Conclusion - Most likely failure mode out of all hypotheses. 5)Recommendations,if required.

Writing the report in an easy to understand way is absolutely critical. Usually the person closest to the analysis is so familiar with the material that conclusions may even seem obvious to them so I've had great success asking an uninvolved, non-technical colleague to review information. Always err on the side of assuming your audience doesn't know much about the theories, equipment, or practice. Pictures and information added with SNAGIT software is super helpful. Write a highlight summary and then include pages and pictures of extensive details in an appendix to not "bore" people with details if they trust you!

What this "AI" facilitated article totally missed, and is covered in detailed depth in my new book, is 1) to turn on your brain / mind and 2) learn how to practice turning on and optimizing your visual interpretation and thinking skills. Of course "AI" can't do any of those things. Want to leave the hard "thinking" to a machine? Then follow this advice as given. Want to keep this experiment we call humanity going? Read my book. The actual FA procedure embedded in the book (Chapter 6) is called The Step Zero Method. Get the book. Read it. Practice the exercises. You will experience your expertise grow sooner!