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Meeting Materials Science & Technology 2019
Symposium Failure Prevention and Unconventional Failures
Presentation Title Using Material Science to Understand Seemingly Random Product Failures
Author(s) Jeff L. Ellis
On-Site Speaker (Planned) Jeff L. Ellis
Abstract Scope Have you ever encountered seemingly random failures of your fielded products? No failure is random, but it takes a fundamental understanding of materials to understand it. For many products the root cause failure is a complex interplay between material structure, processing, and environment. This presentation will first discuss common errors that design engineers make during the material selection process. This will include considering the environment the material experiences throughout its lifecycle, as well as material property deviations from technical data sheet values. Next, a depiction of the interplay between material structure, processing, and environment will be used to illustrate examples of the complexity of fielded product failures. Finally, the strategies that were implemented to fix the real-world failures and manufacture a more robust product will be discussed.
Proceedings Inclusion? Definite: At-meeting proceedings

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

As Designed Does Not Always Equal as Manufactured
Cold Spray for Cavitation Erosion Protection for Hydropower Applications
Common Failures, Uncommon Features
Electrochemical Measurement of Corrosion Protection Using Vapor Corrosion Inhibitors
Failure Analysis of a LORAN C Tower Near Greenland
Failure by Design
Failure Prevention of High Strength Bolts
Failure Severity Mitigation through the Use of Exception-Handling Devices
Human Factors in Control Systems
Investigation of an Amphibious Duck-boat Fracture in Seattle, WA
Laboratory Testing of Major Components in Support of Continued Operation
Leak in Water Line 45 Years in the Making
Metallurgical Failure Analysis of a Fractured Intermediate Coupling
NTSB Recommendations to Prevent Future Transportation Accidents
Radiant Tube Heater Failure Analysis and Resulting Changes to NFPA 54
The Failure Analysis & Prevention of a Large and Critical Extrusion Gearbox : Part 3 - Material, Microstructure & Heat Treatment : Curiosities of Some Gear Teeth
The Power of the "Infinite Smalls" Where Heavy Rude Working Conditions Are Involved !
The Unusual Case of a Not-so-Obvious Brake Line Failure
Using Material Science to Understand Seemingly Random Product Failures
When a Highway Bridge Suddenly Lifts Its Up Without Prior Announcement … !
Wind-induced Failure of 9m Street Lamp Poles

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