Failure Analysis and Root Cause Investigation

AECTL offers comprehensive failure investigation and analysis services, along with a wide range of laboratory-based metallurgical tests across its multiple laboratories in Australia. AECTL is staffed by a diverse team of professionals, including experienced Materials Engineers, Metallurgists, Scientists, Engineering Technologists, and Inspectors certified by AICIP, NACE, WTIA, AINDT, as well as Non-destructive Testing personnel. This multidisciplinary team ensures that the most probable root cause of a failure is accurately determined, and the best preventive measures are recommended.

Moreover, AECTL’s clients benefit from implementing the most cost-effective condition monitoring regimes, which not only comply with regulatory requirements and international standards but also extend the life of their assets. Extending asset usage beyond its design life is environmentally beneficial, as it reduces the overall environmental impact by minimizing waste and resource consumption.

AECTL is accredited according to ISO 17025 for a variety of metallurgical, mechanical, chemical, and NDT-related tests. The Forensic Engineers (Investigators) at AECTL, who conduct failure analyses, are also authorized under the ISO 17025 Accreditation system to perform other types of engineering tests. This additional expertise and qualification of AECTL’s Materials Engineers provide clients with added value in extending the life of their assets.

Given AECTL’s extensive experience across various fields, the company also offers Expert Witness services for third-party audits, dispute resolution, or litigation purposes. As an Expert Witness, AECTL’s team can provide independent opinions on technical matters or consumer products, serve as technical advisors for vendor qualification or approval, ensure conformance to industry specifications, or conduct forensic reviews.

Failure analysis is a methodical process that involves collecting and analyzing data to determine the probable root cause of a failure. This process includes gathering data on operating conditions, performing visual examinations of the failed product or component, conducting fractography, non-destructive testing, and evaluating the mechanical and chemical properties through metallography, microscopy, and spectroscopy. The analysis of these facts and findings leads to a root cause conclusion and recommendations to prevent future failures.

This process is crucial in heavy industries to prevent failures of both affordable and costly components, as such failures can lead to significant production losses, sometimes amounting to thousands or millions of dollars, and potentially cause harm to people or communities. Identifying the root cause and implementing preventive actions reduces the risk of injuries, minimizes downtime, and increases productivity in industries such as mining, oil and gas, offshore operations, shipping, and heavy engineering. Quality-endorsed organizations and insurance companies often mandate failure investigations to mitigate the risk of future failures.