Lecture 1 introduction to failure analysis
- 1. 1 FAILURE ANALYSIS AND MATERIALS TESTING An Introduction
- 2. Failure Analysis 2 Task: To investigate the different types of failures Objective: To understand the cause(s) of failure Significance: To take measures that can prevent them in the future
- 3. 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.
- 4. Failure Analysis Procedure involves a series of examinations to reveal: -Quality of the material -Quality of the fabrication process -Possible abuse during service
- 5. Failure Analysis is Designed to: 1. Identify the Failures Modes - the way the product failed 2. Identify the Failure Site - where in the product failure occurred 3. Identify the Failure Mechanism - the physical phenomena involved in the failure
- 6. Failure Analysis is Designed to: 4. Determine the Root Cause - the trigger point which led to failure 5. Recommend Failure Prevention Methods - corrective action or improvement
- 7. Failure Analysis 7 DRIVE customer returns to Manufacturing/ FA zero, INCREASE quantity Fails/Rejects Results Production and quality, ACCELERATE new product introductions Tools and Techniques Aid in analyses of rejects Understand root cause(s) of failure
- 8. Engineering Products and their Performance 8 Main Stages in the History of an Engineering Design Engineering Product Manufacturing (Commercial Product) Service Conditions (Performance)
- 9. Engineering Products and their Performance 9 Almost every design and useful application devised by the engineer is dictated by the quality of materials used in manufacturing, which limits the performance capabilities of the product.
- 10. Engineering Design-Fabrication- Performance Schematic illustration of the continuity and main steps of the process of engineering design– manufacturing–performance
- 11. Engineering Design- Fabrication-Performance Lifetime of a given product can vary significantly depending upon variables such as: (i) the extent of analysis and experimental development involved in the various stages of design (ii) the quality of materials used to manufacture the product (iii) manufacturing technology (iv) exact knowledge of service conditions
- 12. Materials Selection . Materials Selection is governed: (i) properties relevant to the application (ii) manufacturing constraints (iii) effect of manufacturing procedures on properties (iv) prior incidents of failure (v) maintenance and repair frequency (vi) cost
- 13. Property Evaluation It is possible to evaluate the properties of a failed component by two main types of tests: (i) nondestructive (ii) destructive. Nondestructive tests do not degrade the integrity of the component being tested and primarily carried out to detect flaws and control dimensions. Destructive tests are used to determine certain properties, which are mostly of mechanical nature, such as tensile strength, creep strength, and fatigue strength.
- 14. FA TECHNIQUES Non-destructive FA Techniques optical microscopy (external or internal visual inspection) x-ray radiography (internal x-ray imaging) curve tracing (current-voltage characterization) SAM (detection of delamination) Liquid dye penetrant (detecting cracks at the surface) Magnetic particle inspection (surface flaws in magnetic materials) Ultrasonic inspection (flaw detection and thickness measurement)
- 15. FA TECHNIQUES Destructive FA techniques decapsulation (opening of the IC package) sectioning (cross-sectioning of the sample) SEM/TEM (high magnification real-time imaging) EDX/WDX (uses x-ray for elemental analysis) mechanical testing (hardness and mechanical testing) Auger analysis (surface analysis)
- 16. Quiz #1 1. What are the three stages of the history of an engineering product? 2. Give 3 examples of non-destructive FA techniques. 3. Give 3 examples of destructive FA techniques. 4. Failure analysis is sometimes called __________.
- 17. 17 THE End.