Root Cause Failure Analysis RCFA Training Overview

Duration: 3-4 days

Introduction

If you are a design, quality, or manufacturing engineer or manager, this course will help you realize the benefits you can receive from well-executed fracture analysis. If you are a more experienced fracture analysis practitioner, it will help you improve your ability to interpret and communicate the data provided by the tests that are typically performed during failure analysis.

In this course, we will study concepts and techniques that are useful for a very broad range of materials used in machinery and structural components (not electronic assemblies) that are subject to deformation, fracture, corrosion and wear. Given the importance of human factors in failure analysis, we will also devote about 20% of the course time to the discussion of difficulties inherent in the failure analysis process, personality characteristics and people skills that are helpful in this field, and the common thinking errors. You will receive tips and perform practice exercises that will help you avoid the common pitfalls and think more clearly. The workshop version of this courses uses extended real-life case studies to help you further apply the techniques taught in your own job.

Root Cause Failure Analysis RCFA Training Overview

Related Courses

After completing this course, attendees will be able to:

  • List levels of causes of failures
  • Approach and plan an investigation, write a fracture analysis protocol
  • Articulate and clarify objectives for a root cause failure analysis
  • Set up a failure investigation
  • Describe the key principles of materials science and engineering
  • Apply practical macro and micro fractography
  • Use optical metallography, NDT methods, composition analysis, mechanical tests, and FEA to analyze fractures.
  • Prevent failures
  • Gauge self-consistency in the conclusions of the various tests
  • Read and evaluate root cause failure analysis reports
  • Improve your ability to judge the quality of a failure investigation
  • Make use of failure analysis to improve durability and economy

Understanding Levels of Causes of Failures

  • Physical, mental, latent
  • Time of origin of causes: Design phase, manufacturing, maintenance, use, complex interactions

Getting Set up to Perform a Failure Investigation

  • Understanding human nature
  • Techniques to improve use of our knowledge
  • The failure analysis toolbox
  • Evidence preservation in the lab and in the field
  • Basic visual examination
  • Specimen selection

Use of “control” parts

Principles of Materials Science and Engineering: A Crash Course

  • Atoms, crystals, grains
  • Anisotropy
  • The process, structure, properties triangle

Practical Macro and Micro Fractography

  • Crack appearance in different loading geometries
  • Axial
  • Bending
  • Torsion
  • Direct shear
  • Contact loading
  • Classical Microscale Features
  • MVC
  • Cleavage
  • Intergranular
  • Striations
  • Dealing with the lack of published data on polymeric fractography

Fracture Analysis Techniques:

  • Optical metallography
  • NDT methods
  • Composition analysis
  • Mechanical tests
  • FEA in fracture analysis

Preventing Failures

  • Quantitative determination of an adequate hardening heat treating specification for steel components
  • How to specify steel for stampings
  • “Guess and Hope,” “Guess and Test,” and “Comprehensive Engineering” approaches to design

Putting It All Together

  • Evaluating self-consistency in the conclusions of the various tests
  • Putting together the component pieces of the analysis into a cohesive and incisive whole
  • How to read and evaluate root cause failure analysis reports
  • (Workshop only): Extended Case Studies
  • Wrap-up: Course recap, Q/A, and evaluations

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