Metallurgical failure analysis laboratory

Metallurgical failure analysis helps understand the reasons behind a metal failure. This analysis begins with a visual and macroscopic examination of the material, followed by sample preparation for microscopic observation (optical, scanning electron microscopy and X-ray diffraction) to analyze the structure and composition of the sample.

The results of these analysis help the laboratory identify the type of failure, such as corrosion, fatigue, fracture, etc.

Metallurgy focuses on the study of the physical and chemical properties of metals and alloys, as well as on the manufacturing and development of new materials for specific applications.

Metallography is a specific analysis technique that involves preparing metal samples for microscopic analysis. It makes it possible to examine their structure, composition and quality. Metallography is essential for characterizing the microstructures of metals, which is useful for understanding their mechanical behavior and susceptibility to corrosion or other degradation phenomena, namely metallurgical failures.

Filab's expertise in metallurgy is thus strengthened by its metallography expertise. Through this metallurgical expertise, the laboratory is able to carry out analysis of metal structures in various tests.

Fracture surface analysis and fractography are two techniques used to analyze material failure. Fracture is one of the ways materials can fail.

The analysis of fracture surface focuses on the macroscopic examination of the fracture surface, while fractography examines the microstructure of the fracture surface at the microscopic scale. This difference makes it possible to obtain complementary information about material failure.

Fractography is particularly useful for materials with a fine or complex structure, while fracture surface analysis is more applicable to materials with a simpler macroscopic structure. By combining these two techniques, the laboratory can gain a more complete understanding of material failure.

Manufacturers face many issues related to metal alloy failures, which require a multidisciplinary approach.

Resolving metal alloy failures makes it possible to pursue continuous improvement in order to optimize product performance and reliability while minimizing environmental impacts and ensuring safety.

Detecting failures, understanding their complex mechanisms, and carefully selecting materials are at the heart of industrial challenges. FILAB offers failure analysis and support in research and development.

Some specific metal alloys may experience characteristic failures, and the alloy composition can influence the type of failure encountered.

• Stainless Steel (Austenitic)

Stress corrosion cracking (SCC): Chloride environments can induce cracks in stainless steels austenitic, in the presence of internal or applied stresses.

• Aluminum Alloys

Galvanic corrosion: When aluminum alloys are in contact with a metal such as stainless steel, and in the presence of an electrolyte, aluminum may undergo accelerated corrosion due to the electrochemical potential difference between the metals.

• Titanium Alloys

Pitting corrosion: Although titanium alloys are extremely corrosion-resistant, in very aggressive environments, for example in the presence of chlorides at high temperature, they may undergo localized corrosion.

• Steels

Atmospheric corrosion: Steels, if not properly protected, may undergo rapid corrosion when exposed to the atmosphere, particularly in humid or saline environments, leading to rust formation.

• Nickel Alloys

High-temperature creep: Nickel-based alloys, under extreme stresses and at very high temperatures, may deform slowly.

• Bronze

Fatigue: Bronze components may fail due to fatigue as a result of repeated cyclic loads.

Each alloy has unique properties that influence its behavior under different operating and environmental conditions. Understanding the failure mechanisms specific to each type of alloy is essential for material selection and component design.

Metal alloys can experience different types of failures depending on their composition, heat treatment, use, and the environment in which they are found. Here are the main types of failures encountered in metal alloys:

• The fatigue of a material, and here of metal, refers to the progressive failure of a material under repeated or fluctuating stresses that are often well below the material's yield strength.

• Corrosion is the degradation of metals caused by a chemical reaction with their environment.

• Wear is the gradual loss of material from the surface of a metal due to physical contact and relative motion.

• Stress corrosion cracking is a failure caused by the combination of corrosion and tensile stresses.

• Creep is the slow, permanent deformation of a material under constant stress at high temperature.

• Hydrogen embrittlement is a process by which metals become more brittle and prone to cracking in the presence of hydrogen.

• Temper embrittlement occurs in certain alloy steels which, when exposed to certain intermediate temperatures, can lose their toughness.

These types of failures show the importance of choosing the right alloy for a specific application, as well as the importance of heat treatment, design, and maintenance in the service life of metal components.