Root Cause Analysis of Component Failure Training

Root Cause Analysis of Component Failure Training

Course Delivery

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Course Overview:

Root Cause Analysis of Component Failure Training Course Description

If you are a design, quality, or manufacturing engineer or manager, this Root Cause Analysis of Component Failure Training 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 Root Cause Analysis of Component Failure Training 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.

Customize It:

• If you are familiar with some aspects of this Root Cause Analysis of Component Failure Training course, we can omit or shorten their discussion.
• We can adjust the emphasis placed on the various topics or build the Root Cause Analysis of Component Failure Training course around the mix of technologies of interest to you (including technologies other than those included in this outline).
• If your background is nontechnical, we can exclude the more technical topics, include the topics that may be of special interest to you (e.g., as a manager or policy-maker), and present the Root Cause Analysis of Component Failure Training course in manner understandable to lay audiences.

Related Courses:

Root Cause Analysis of Systems Failure Training Overview
Industrial Statistics Training

Root Cause Analysis of Component Failure Training – Objectives:

Upon completing this Root Cause Analysis of Component Failure Training course, learners will be able to meet these objectives:

• 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

Root Cause Analysis of Component Failure Training – Course Content:

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 (“ductile dimples”)
•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

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