Failure & Forensics
Materials & Metallurgy Engineering
Materials and metallurgical support for determining how material condition, degradation, corrosion, welding, heat treatment or manufacturing defects contributed to equipment damage or failure.
- UEI
- ZR3PJZEA7A21
- CAGE
- 174X8
- Independence
- Findings challenged before release
- Deployment
- Remote response within 24 hours
What This Discipline Covers
Scope of the technical capability.
Materials and metallurgical support for determining how material condition, degradation, corrosion, welding, heat treatment or manufacturing defects contributed to equipment damage or failure.
- Failure metallurgy
- Metallography
- Fractography
- Corrosion assessment
- Weld integrity
- Materials selection
- Hardness and microstructure review
- Laboratory analysis coordination
- Manufacturing defect assessment
Problems The Technical Lead Solves
The questions this discipline is engaged to answer.
- 01
Cracking
- 02
Corrosion
- 03
Fracture
- 04
Weld failures
- 05
Material selection disputes
- 06
Heat treatment issues
- 07
Manufacturing defects
- 08
Laboratory supported failure analysis
Equipment And Systems
Assets this Technical Lead has worked on directly.
- Pressure equipment
- Piping
- Welds
- Shafts
- Gears
- Fasteners
- Castings
- Forgings
- Structural components
Industries And Environments
Operating environments where this experience was built.
- Power
- Oil and gas
- Chemical and process
- Manufacturing
- Infrastructure
Diagnostic And Investigation Methods
How the technical work is actually performed.
- Evidence preservation and chain of custody
- Field examination and dimensional verification
- Fractography and damage mechanism assessment
- Root cause and root cause failure analysis
- Hypothesis testing against operating data
- Engineering calculation and fitness for service screening
Tools Capability
The platforms, instruments and measurement methods used on assignments.
These platforms, instruments and methods are used to produce evidence that holds up under audit, underwriting review and cross examination.
Laboratory Examination
Scanning electron microscopy with EDS
Fracture surface morphology and corrosion product identification to establish failure mechanism.
Optical metallography
Microstructure, heat treatment condition, weld quality and creep or fatigue damage assessment.
Mechanical testing
Tensile, impact, hardness and fracture toughness testing against specification.
Chemical analysis and PMI
Composition verification and confirmation of material substitution.
Corrosion and Degradation Assessment
Damage mechanism review to API 571
Identification of corrosion, cracking, creep, embrittlement and environmental damage mechanisms.
Electrochemical and corrosion testing
Corrosion rate and susceptibility evaluation supporting remaining life assessment.
Field Material Evidence
Replication metallography and portable hardness
In situ material condition assessment without removing equipment from service.
Portable XRF alloy verification
On site confirmation that installed material matches the specified grade.
3D scanning and macro photography of fracture surfaces
Permanent record of the failed part geometry and fracture appearance before sectioning.
Evidence Handling and Dispute Support
Chain of custody and evidence logging
Documented handling of recovered samples from site to laboratory to storage.
Joint destructive testing protocols
Sectioning and testing agreed with other parties so the result is accepted by all sides.
BlackOut Power / TerraTolga Proprietary Capability
- Engineering Records Intelligence
Material certificates, welding records and specifications reconciled against what was actually installed.
- FMECA Engine
Material failure modes placed in the context of the wider equipment and system.
Codes And Standards
Frameworks applied to the analysis.
- ASME BPVC Sections I, V, VIII and IX
- ASME B31.1 and B31.3
- API 579 fitness for service
- API 510, 570 and 653
- NFPA 921 and NFPA 70E where applicable
- API 571 damage mechanisms
- ASTM E3, E407 and E1820 examination and toughness practice
Credentials And Qualification
The professional basis for this discipline.
- 01
Degreed engineering background with industrial operating experience
- 02
Professional engineering registration or equivalent recognized credentials
- 03
Code and standards qualification relevant to the equipment examined
- 04
Expert report and testimony experience in disputed matters
Representative Professional Experience
Assignment types this discipline supports.
- 01
Root cause investigation of a catastrophic rotating equipment failure with recovery planning
- 02
Forensic assessment of pressure boundary rupture including metallurgical and operational analysis
- 03
Multidisciplinary loss investigation coordinating mechanical, electrical, and process specialists
- 04
Independent review of an opposing technical opinion in a contested claim
Assignment descriptions are generalized to protect client confidentiality. Specific references can be discussed during scoping where permissions allow.
Multidisciplinary Interfaces
Disciplines this work commonly coordinates with.
- Mechanical & RCA
- Inspection
- NDT
- Reliability
- Fire & Explosion
Discuss a materials & metallurgy assignment.
Initial conversations are confidential and without obligation. We will confirm independence before scope is discussed.