lecture 1 introduction to failure analysis
TRANSCRIPT
FAILURE ANALYSIS AND MATERIALS TESTING
An Introduction
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Failure Analysis
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
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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.
Failure Analysis
Procedure involves a series of examinations to reveal:
-Quality of the material
-Quality of the fabrication process
-Possible abuse during service
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
4. Determine the Root Cause
- the trigger point which led to failure
5. Recommend Failure Prevention Methods
- corrective action or improvement
Failure Analysis is Designed to:
Failure Analysis7
Manufacturing/Production
FA
Tools and Techniques
Aid in analyses of rejects
Understand root cause(s) of failure
Fails/Rejects
DRIVE customer returns tozero, INCREASE quantityand quality, ACCELERATEnew product introductions
Results
Engineering Products and their Performance
Main Stages in theHistory of anEngineering Product
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Engineering Design
Manufacturing(Commercial Product)
Service Conditions(Performance)
Engineering Products and their Performance9
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.
Engineering Design-Fabrication-Performance
Schematic illustration of the continuity and main steps of the process of engineering design–manufacturing–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
Engineering Design-Fabrication-Performance
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
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.
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)
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)
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 __________.
THE End.
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