500 years before Christ, Confucius said: "A man who has committed a mistake and doesn't correct it is committing another mistake".
An insight with which we wholeheartedly agree. For this reason we examine all damage in great detail and undertake damage analyses on components subjected to dynamic or static loads. Our results will help you to optimise material development, material selection, design, manufacture or forms of operation. Whether fatigue, the action of force or corrosion, we find the cause. Damage analysis at Quality Analysis is undertaken based on the VDI standard 3822.
Why do we combine analysis methods?
It is essential to combine various analysis methods to obtain a holistic, informative analysis result. The following analysis methods are used at Quality Analysis:
- Macroscopic assessment in the stereo microscope
- Scanning electron microscopy for the high-resolution depiction of surface structures (topography) and material differences as well as the elemental analysis of inclusions
- Light microscopic microstructure analysis on prepared specimen (etched)
- Spark emission spectroscopy (OES) for determination of the material and checking the alloy composition
- Hardness testing to analyse heat treatment
SYMPTOMS AND CAUSES OF DAMAGE
Damage to metal products and metallic materials has various causes. These causes include mechanical, thermal or tribological exposure, corrosion and damage to welded joints.
We assess fractures in relation to the fracture mechanism triggered by
- Mechanical exposure: overload fracture, fatigue fracture
- Thermal exposure: hot crack, solidification crack, thermal shock crack
- Exposure to corrosion: intercrystalline corrosion, stress corrosion, hydrogen induced cracks
We use scanning electron microscopy to depict and analyse fracture surfaces.
defects in welded joints
Welded joints always represent a weak spot in the component. The application of heat causes changes in the microstructure which can cause numerous defects when combined with operating conditions:
- Material-related: hot cracks, cold cracks, etc.
- Manufacture-related: lack of fusion, incomplete joint penetration, seam and edge offset, etc.
- Operation-related: force fractures, fatigue fractures, corrosion damage, etc.
We analyse welded joints in an etched specimen using light and scanning electron microscopy as well as hardness testing.
The corrosion of a component often results in significant degradation of the function of the metal, the entire component or the technical system in which it is installed.
It is necessary to identify the cause of the corrosion and the type of corrosion so that rectification measures can be initiated.
For this purpose, after the macroscopic, holistic assessment of the component, we use scanning electron microscopy and light microscopy.
wear / tribology
Wear causes the loss of material from the surface of a body mostly due to mechanical action. This undesirable abrasion of the surface occurs often on gearwheels, bearings, couplings, gearboxes, etc.
The determination of the wear mechanisms provides information on the measures that must be taken to prevent premature wear and subsequent component failure.
The usage of all light microscopic and scanning electron microscopic analysis methods is essential here. We also use digital and laser scanning microscopy to depict and measure signs of wear.
forensic material testing
For forensic material testing we rely on the experience and specialist skills of our employees as well as the expertise and capability of our accredited test laboratory. We investigate and assess the damage based on the rules and techniques as per VDI 3822 and rely on the networking between our specialist areas for more in-depth analysis results to clarify the cause of the damage.
We can analyse the following damage:
- Mechanical damage (failure due to fatigue or the application of force)
- Thermal damage
- Wear damage
- Corrosion damage
- Hydrogen induced damage
WHY DAMAGE ANALYSIS WITH QUALITY ANALYSIS IS WORTHWHILE
We have a very wide range of saws and cutting machines for the preparation of even very large components made of different materials and with complicated geometries for subsequent analyses.
BEST SOLUTIONS AND EMPHASIS ON RESULTS
Often it is necessary to combine various systems and solutions to obtain the best result for a specific analysis. Here our customers profit from the sound experience and expertise of our experts and the many different analysis systems available to us.
DOCUMENTATION AND EVALUATION
The analysis results we produce are combined in a clearly structured manner in a test report. Here it is particularly important for us that the individual analysis steps are transparent and the results are comprehensively depicted and explained using images. We also address the findings obtained from the related damage (lessons learnt) and provide an overview of possible rectification measures
ACCREDITED TEST LABORATORY
Test laboratory accredited in accordance with DIN EN ISO/IEC 17025