Fracture Analysis Services

There are many factors that can contribute to Fractures. For example these may include:

• Brittle fractures caused by low temperatures, high strain rates, or the presence of hydrogen
• Environmental conditions, such as temperature, humidity, chemical exposure, and corrosion,
• Processing Defects such as improper heat treatment, forging defects, casting porosity, or insufficient material thickness.
• Poor design choices, such as sharp corners, abrupt changes in geometry, or inadequate fillets, can create stress concentrations that promote crack initiation and propagation. 8.
• Metals can fracture under sudden impact or shock loading, especially if they are not designed to withstand such loading conditions.

Fracture Analysis uses Failure Investigation to determine the circumstances surrounding a fracture, including the conditions under which it occurred and the history of the component. It also involves gathering information about the operating conditions leading up to the failure.

By examining the fracture surface, the specific mechanism of failure can be determined. Different fracture mechanisms in metals can be analysed through fracture analysis, and may include:

• Ductile fracture
• Brittle fracture
• Fatigue failure
• Stress corrosion cracking
• Hydrogen embrittlement

The main goal of fracture analysis is to identify the root cause or causes of the failure. This requires considering factors such as design flaws, material defects, manufacturing processes, and environmental and operational conditions.

Fractography testing techniques aim to identify the fracture morphology of a component and gain insights into the fracture mechanism.

Fractography plays a crucial role in analysing the fracture surface for damage and cracks. When a material is fractured or broken, it exhibits certain characteristics on the surface that indicate signs of failure. These characteristics may include

• Ductile dimples
• intergranular cracking,
• fatigue-induced scratches or grooves,
• cleavage of the material.

Fractography allows us to uncover any underlying imperfections, defects, or flaws within the material. Identifying these flaws is essential as they can have implications for future manufacturing processes and may lead to further failures in real-service conditions. By analysing and addressing these underlying imperfections, we assist our customers in enhancing the design, safety, and longevity of their products.

Testing the durability of a material is an essential aspect of examining fractures. When a material possesses great strength, the chances of it fracturing or breaking during use are significantly reduced.

However if a material is weak or brittle, it is highly susceptible to breaking under stress or fatigue. Brittle fractures can occur suddenly and without warning, potentially leading to catastrophic consequences upon failure.

By analysing the strength and toughness of the material, we gain insights into its limitations and points of vulnerability. This valuable information helps determine whether the material is suitable for a specific application or service condition.

We use a variety of mechanical test methods to assess the material’s strength and durability, such as tensile testing, hardness and microhardness testing, impact testing, and bend testing.