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Week - 1 |
Introduction to failure analysis: basic concepts, types of engineering failures, and the importance of failure analysis. |
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Week - 2 |
Stages of systematic failure analysis: background information gathering, identification of service conditions, sampling, and preservation of evidence. |
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Week - 3 |
Failure investigation methods: visual inspection, nondestructive testing, chemical analysis, metallography, and mechanical testing. |
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Week - 4 |
Stress concentration, residual stresses, and fundamentals of fracture mechanics; crack initiation and propagation. |
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Week - 5 |
Ductile and brittle fracture mechanisms; macroscopic and microscopic examination of fracture surfaces. |
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Week - 6 |
Fatigue failure: cyclic loading, crack initiation and propagation, and factors affecting fatigue life. |
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Week - 7 |
Identification of fatigue fractures; case studies of mechanical and thermal fatigue. |
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Week - 8 |
Creep and high-temperature failures: creep mechanisms, stress rupture, and microstructural changes. |
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Week - 9 |
Corrosion-related failures: general and localized corrosion, stress corrosion cracking, and hydrogen embrittlement. |
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Week - 10 |
Wear and surface damage: adhesive and abrasive wear, erosion, fretting, and contact fatigue. |
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Week - 11 |
Manufacturing-related failures: evaluation of defects arising from casting, metal forming, machining, and heat treatment. |
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Week - 12 |
Failure analysis of welded joints: weld imperfections, the heat-affected zone, and cracking mechanisms. |
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Week - 13 |
Failure analysis of shafts, gears, bearings, and fasteners; effects of design, material selection, and operating conditions. |
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Week - 14 |
Root cause analysis, failure prevention approaches, and technical reporting; case study presentations and overall review. |