Failure Analysis And Prevention

The course content is designed to systematic understanding on various aspects related with failure such as fundamental sources of failure of mechanical components, industrial engineering tools relevant to failure and failure analysis, general procedure of failure analysis through sample collection, preparation and preservation, testing, macro and microscopic observation of fracture, mode of fracture, metallographic procedure and image analysis, use of fracture mechanics and fracture toughness principles in failure analysis and analysis findings and report/recommendation writing. Presentation will include case studies to communicate concepts and procedures effectively. Case studies will be taken up from failure analysis of weld joints in different sectors.

INTENDED AUDIENCE :UG and PG Student, Research Scholar & Practicing EngineersPRE-REQUISITES : Nil
INDUSTRY SUPPORT :Heavy engineering and pressure vessel industry, power plants

COURSE LAYOUT

Week1:1. Introduction: Need and scope of failure analysis and prevention2.Introduction: Engineering disasters and understanding failures3.Fundamental sources of failures: Deficient design I4.Fundamental sources of failures: Deficient design II5. Fundamentalsources of failures: Deficient design III and upgrading of a part
Week2:1.Fundamental sources of failures: Imperfections in base metals2.Fundamental sources of failures: Improper Manufacturing I3.Fundamental sources of failures: Improper Manufacturing II4.Fundamental sources of failures: Improper Manufacturing III5.Fundamental sources of failures: Improper Manufacturing IV and improper service conditions
Week3:1. Fundamental sources of failures: Poor assembly, service andmaintenance2.Industrial engineering tools for failure analysis:Pareto diagram3.Industrial engineering tools for failure analysis:Fishbone diagram and FMEA4.Industrial engineering tools forfailure analysis: FMEA5.Industrial engineering tools for failure analysis: Fault tree analysis
Week4:1.Industrial engineering tools for failure analysis: Reliability-I2.Industrial engineering tools for failure analysis: Reliability-II3.General procedure of failure analysis: Steps4.General procedure of failure analysis: Background information collection5.General procedure of failure analysis: Preliminary examination
Week5:1.General procedure of failure analysis: NDT for failure analysis2.General procedure of failure analysis: Destructive testing3.General procedure of failure analysis: DT, selection, preservation, cleaning & sectioning of samples4.General procedure of failure analysis: Macroscopy of fracture surfaces-I5.General procedure of failure analysis: Macroscopy of fracture surfaces-II
Week6:1.General procedure of failure analysis: Macroscopy of fracture surfaces-III2.General procedure of failure analysis: Macroscopy of fracture surfaces-IV3.General procedure of failure analysis: Microscopy of fracture surfaces4.General procedure of failure analysis: Metallography of failed components5.General procedureof failure analysis: Determination of type of fracture I
Week7:1.General procedure of failure analysis: Determination of type of fracture II2.General procedure of failure analysis: Determination of type of fracture III and chemical analysis3.General procedure of failure analysis: Application of fracture mechanics I4.General procedure of failure analysis: Application of fracture mechanics II5.General procedure of failure analysis: Simulated test and analysisof evidences/results
Week8:1.General procedure of failure analysis: Questions for analysis2.General procedure of failure analysis: Reporting failure analysis and failure analysis of welded joint3.General procedure of failure analysis: Failure analysis of weld joint4.General procedure of failure analysis: Examples of failure analysis5.General procedure of failure analysis: Embrittlement of steels