TCR Arabia's failure analysis strength is in evaluating high temperature and high pressure failures. The Failure Analysis Team at TCR Arabia has experience in the materials, failure analysis, metallurgical, welding, quality assurance, and forensic engineering fields and is conducted by engineers holding advanced degrees in metallurgy, and mechanical, civil, chemical, and electrical engineering.

TCR Arabia works with our clients to plan the failure analysis before conducting the investigation. A large amount of time and effort is spent carefully considering the background of failure and studying the general features before the actual investigation begins.

Cause of failure is determined using state-of-the-art analytical and mechanical procedures and often includes simulated service testing. A combination of analysis and physical testing locates problems and provides recommendations for solutions.

Our initial step to perform failure analysis begins with visually studying the failed part and asking detailed questions regarding associated parts, plant environment and operational procedure. A complete evaluation sequence of the failure investigation steps are summarized as under:

• Collection of background data and selection of samples
• Preliminary examination of the failed part
• Complete metallurgical analysis of failed material
• A through examination of the failed part including Macroscopic and Microscopic examination and analysis (electron microscopy may be necessary)
• If necessary tests also include Weld Examination, Case Depth, Decarburization Measurement, Coating/Plating Evaluation, Surface Evaluation and/ or Grain Size Determination
• Chemical analysis (bulk, local, surface corrosion products, deposits or coating and microprobe analysis)
• Tests to simulate environmental and physical stress that may have played a role in the failure
• Selection and testing of alternative products and/or procedures that will significantly improve performance
• Analysis of fracture mechanics.
• On-site evaluation and consulting services
• Analysis of all the evidence. Formulation of conclusions and writing the report (Including recommendations).

In the course of the various steps listed above preliminary conclusions are often formulated. If the probable fundamental cause of the metallurgical failure becomes evident early on in the examination, the rest of the investigation focuses on confirming the probable cause and eliminating other possibilities. The metallurgical failure analyst compiles the results of preliminary conclusions carefully considering all aspects of the failure including visual examination of a fracture surface, the inspection of a single metallographic specimen, and the history of similar failures.

Our partner company, TCR Engineering in India has completed more than 300 failure investigation assignments, including 50 major projects on manufacturing or metallurgical failure analysis on ASME boiler and pressure vessels, Aircraft /Aerospace, Gas turbine engine components, Oil and gas transmission pipelines, Food processing equipments, Heat exchangers, Medical supplies, Automotive components, Refineries, Petrochemical plants, Offshore structures, Industrial machinery, Weldments and Ships.

View some case study examples of our noteworthy failure investigation projects:
· Primary Super Heater R-4 Zone Tube of a 140 Mw Boiler
· Radiant Coil of a Cracker Furnace H-130 Refinery
· 8th Stage Blade of a Steam Turbine
· Sac Plant Piping Going to V-801
· Integral Pinion Shaft of a Cement Mill

You can also download failure analysis case study examples.

TCR Arabia's dedicated engineering and metallurgical consulting team in Saudi Arabia is a perfect partner for solving manufacturing and product quality problems. Several senior consultants with many years´ experience are available to help and advise on corrosion or materials selection queries. The metallurgical consulting team also advise on welding engineering, heat treatment problems, verifying product integrity, measuring performance and determining end of life to enhance product performance and quality.

From initial product design, through final production, the in-depth engineering consulting services ensures that clients are producing the best possible product. Areas of consulting assistance include:

• Investigation of a Mechanical or Product Failure
• Assist in cost-benefit analysis post a failure analysis study
• Estimate the remaining service life of a product or machine component
  

• Sourcing Material and Products from India

• Determining the right material for a product
• Assist to solve product quality problems
• Compare vendor or competitive products
• Advise on heat treatment for most grades of steel including case hardening, hardening and tempering, annealing and stress reliving
• Ensure product compliance to RoHS and WEEE
• Prepare material and process specifications for in-house quality control
• Investigate the effect of environmental conditions on a product or material
• Corrosion testing, welding evaluations, corrosion testing and corrosion related investigations
• Expert witness and opinion assistance in case of trade conflicts, materials disputes, and litigation issues

• Manage on-site Quality Control including Non Destructive Testing Projects
• Develop Automated UT TOFD Scan Plan and Procedures

• Developing custom test setup as required by client-prepared specifications
• Identify equivalents between Indian (IS) and foreign specifications
• Research and assist in the purchase of metallurgical laboratory equipment

• Processing and microstructure-property relationships of both ferrous and non-ferrous alloys
• Microstructural simulation by phase-field techniques
• Inter-Metallic Phase Determination
• Scanning Electron Microscopy (SEM), EDAX, TEM^*
• Surface Analysis (XPS, ESCA, Auger), Infrared Spectroscopy (FTIR), Electrochemistry, Thermal Analysis (TGA, DSC, TMA, DMA), Mass Spectroscopy (RGA) and X-ray Diffraction (XRD)^*
• Create a custom Metallurgical Image Analysis Software

^* Some tests are conducted in eductational institutions or at our associate lab in USA. The end goal continues to be in providing the best evaluation in a cost-effective manner.

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