Failure Analysis Services for Aerospace & Oil & Gas
Rapid, Accredited Root-Cause Investigations Decisions You Can Act On
When components crack, deform, leak, or wear out early, AADFW provides end-to-end failure analysis that finds the mechanism, isolates the cause, and recommends corrective action, fast. We blend accredited testing, expert metallurgists, and production-speed turnaround so your team can contain risk and return to service.
Talk to a Testing Specialist: 817-540-0153
Talk to a Testing Specialist: 817-540-0153
Why Failure Analysis Matters
In flight-critical and high-pressure environments, small defects escalate into safety, reliability, and cost exposure. A disciplined investigation confirms the failure mechanism (fatigue, overload, corrosion, embrittlement, wear) and the root cause (material, design, process, or service). Defensible evidence supports MRB decisions, supplier claims, OEM/FAA expectations, and rapid corrections to prevent recurrence.
AADFW’s Approach: Precision, Speed, and Proof
- Accredited & precise: Work performed under ISO/IEC 17025 quality controls with calibrated equipment and documented uncertainty.
- Faster results: Triage fast, prioritize the most probative tests, and deliver concise, board-ready reports that keep critical programs moving.
- Trusted partner: Engineers and QC managers choose AADFW for investigations that stand up to audits—and translate data into clear actions.
What We Investigate (Typical Failure Modes)
- Fatigue & Fracture: High-cycle/low-cycle fatigue, stress-corrosion cracking (SCC), brittle/ductile overload, hydrogen-assisted cracking.
- Corrosion & Environment: Uniform, pitting, crevice, galvanic, MIC; coating breakdown; sour-service (H₂S/CO₂) effects.
- Manufacturing & Materials: Inclusion-driven defects, improper heat treat, wrong material, weld defects (lack of fusion, porosity, undercut).
- Wear & Surface: Adhesive/abrasive wear, fretting, erosion, cavitation, galling.
- Assembly & Service: Misalignment, torque/preload issues, thermal exposure, design stress risers.
Failure Analysis Capabilities (Technical Scope)
- Evidence Preservation & Triage – Receipt inspection, photo-documentation, non-destructive screening (LPI/MPI), and sectioning plans that protect key features.
- Fractography – Stereo microscopy and SEM fractography to identify initiation sites and crack growth mode; EDS chemistry on inclusions/contaminants.
- Metallography – Macro/micro examination, grain size, inclusion rating, case depth, HAZ/weld integrity, coating cross-sections.
- Mechanical Testing – Tension, hardness mapping (HB/HRC/HV), Charpy V-Notch, bend tests to verify strength/toughness versus specification.
- Chemical Analysis – OES for alloy ID, Combustion (C/S), Inert Gas Fusion (O/N/H) for interstitials tied to embrittlement or porosity.
- Corrosion Evaluations – Salt Spray exposure, scribe creepage, blister/rust ratings; deposit/scale ID.
- Special Studies – Residual stress indications, microcleanliness, coating adhesion, fracture toughness (as specified).
- Documentation & Chain of Custody – Full traceability, test plans, calibration certificates, and evidence logs included.
Our Process: From Symptom to Solution
- Intake & Objective Setting – Define what “solved” looks like (containment, disposition, redesign, supplier QA).
- Non-Destructive Screening – Preserve evidence; map damage without altering fracture features.
- Targeted Testing Plan – Select highest-value tests to confirm/deny hypotheses quickly.
- Root-Cause Synthesis – Correlate fractography, metallurgy, chemistry, and service history.
- Actionable Report-Out – Concise executive summary, mechanism + cause, ranked corrective actions, and supporting data appendix.
- Follow-Up Support – Engineering review, supplier communication packages, and verification testing of fixes.
Industries We Support
- Aerospace: Fasteners, landing gear, actuators, airframe structures, engine-adjacent hardware—aligned to OEM/FAA expectations.
- Oil & Gas: Pipeline/tubulars, valves, pressure components, weld overlays/cladding; sour/CO₂/subsea service conditions.
- Manufacturing: Mission-critical assemblies where downtime and risk must be minimized.
Trusted by engineers and QC managers across mission-critical industries.
Accreditations & Compliance
AADFW operates to ISO/IEC 17025 and supports Nadcap-driven program requirements using applicable ASTM/ASME/AMS/ISO methods (e.g., ASTM E3/E407 metallography, ASTM E18 hardness, ASTM E8/E21 tension, ASTM E23 Charpy, ASTM E45 inclusions, ASTM B117 salt spray). Our deliverables are audit-ready for OEM, prime, and regulatory review.
Deliverables You Can Use
- Executive Summary – Mechanism, root cause, and recommended actions in one page.
- Technical Findings – Methods, observations, images, spectra, and micrographs.
- Conformance Check – Comparison to drawings/specs and acceptance criteria.
- Corrective Action Roadmap – Practical containment, process changes, material or design updates, and verification plan.
Why Engineers Choose AADFW
- Accredited & precise investigations with calibrated, traceable data.
- Faster turnaround that supports MRB gates and production schedules.
- Trusted partner who communicates clearly and protects evidence.
- Expert metallurgists who turn complex data into clear go/no-go decisions and actionable fixes.
Call to get a Quote
Stop the recurrence—get the data and guidance to fix it. Call to get a Quote and schedule your failure analysis today.
Talk to a Testing Specialist: 817-540-0153
Talk to a Testing Specialist: 817-540-0153