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Chapter 1 Introduction Dell

This document discusses failure analysis, which investigates the causes of product or process failures to prevent future recurrences. It notes that failures can result in financial losses, injuries, and deaths. The document classifies failures and discusses common causes such as defects, improper design, manufacturing issues, and service abnormalities. Examples of structural failures that injured or killed people are provided to illustrate why failure analysis is important.

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Muhd Akmal
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© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
25 views

Chapter 1 Introduction Dell

This document discusses failure analysis, which investigates the causes of product or process failures to prevent future recurrences. It notes that failures can result in financial losses, injuries, and deaths. The document classifies failures and discusses common causes such as defects, improper design, manufacturing issues, and service abnormalities. Examples of structural failures that injured or killed people are provided to illustrate why failure analysis is important.

Uploaded by

Muhd Akmal
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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FAILURE ANALYSIS-INTRODUCTION

MAHFODZAH MD PADZI
DEFINITION
•Failure Analysis is an investigation carried
out to determine the cause of
failure of a certain product or equivalently
the mistake in the continuous process of
engineering design-manufacturing-
performance in order to prevent its
recurrence in the future.
IMPORTANCE OF FAILURE ANALYSIS
▪ Financial loss
▪ Personal injury and death
▪ Improvement
FAILURE
▪ Failure is a general ▪ Failures can be broadly
classified into the following
term for a condition four categories:
in which a member is
subjected to plastic 1. damage
deformation 2. Fracture
3. break
4. rupture.
Terengganu stadium collapses, June 2009 (and
AGAIN, in February 2013)
5 locals injured, no fatalities

Penang second bridge collapse, June 2013


1 killed, 3 injured
MRT accident in Subang Jaya, 2013

300 tonne beam crushed three people in Kota


Damansara, 2014
Penang Jetty tragedy, July 1988
32 killed, 1,634 injured

Highland Towers collapse, December 1993


48 deaths
WHY STRUCTURES FAIL?
▪ Negligence during
design, construction, or
operation of the
structure.
▪ Application of the new
design or material
▪ Environment
▪ Maintenance Occurrence of failures and measures to prevent them
FAILURE

Classification of failures according to failed members


Classification of failures according to cause
EFFECT
▪ Injuries to personnel
▪ Damage to property
▪ Shutdown of an entire plant
▪ Loss of production
▪ Ecological problems such as release of hazardous
materials
▪ Expensive and prolonged litigations affecting the
credibility of the manufacturers and the reliability of
their products
ONE OF THE MOST TRAGIC BRITTLE FAILURES WAS THAT OF A MOLASSES TANK THAT FAILED IN BOSTON ON JAN.
15, 1919 AND FLOODED THE CITY WITH 2.3 MILLION GALLONS OF MOLASSES, DROWNING PEOPLE AND HORSES
AND KNOCKING OVER THE BOSTON ELEVATED RAILWAY STRUCTURE.
THE TRAGEDY AT BHOPAL, INDIA ON DEC. 3, 1984, WHICH CLAIMED THE LIVES OF OVER
2000 PEOPLE AND MAIMED MANY DUE TO THE RELEASE OF THE POISONOUS METHYL
ISOCYANATE GAS
COMMON CAUSES
Mechanical Electrical Environment

➢ Defects
➢ Design
➢ Manufacturing
➢ Service Abnormalities
➢ Sabotage
DEFECT
A defect is, by definition, a condition
that must be removed or corrected,
while an imperfection or flaw is a
condition that does not necessarily
result in a defective part or failure.

Causes:
i) Improper design
ii) Defective manufacture
iii) Improper inspection
iv) Environmental effects
IMPROPER DESIGN
MANUFACTURING PROCESS
SERVICE ABNORMALITIES

abnormalities could be unexpected


overloads, temperature changes,
environment changes, undesirable
vibrations, and so forth.
SERVICE ABNORMALITIES

abnormalities could be
unexpected overloads,
temperature changes,
environment changes,
undesirable vibrations, and so
forth.
Fig. 2.29 Damage to fan blades of an aircraft engine by a foreign object

Fig. 2.30 Hip prosthesis failed by fatigue following fretting. Source: Ref 8.
With kind permission of Chapman and Hall Limited

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