Decoding Defects: Failure Analysis Using X-ray CT

What is failure analysis? Why do we need it, which technique should we use, and when?
In this episode, we will start with an introduction to Failure Analysis, an investigational method to identify and understand the root causes of failure for materials and products. We will review common nondestructive testing methods used for failure analyses and compare their advantages and limitations. Then, we will look deeper into failure analysis using X-ray CT. X-ray CT often reveals crucial insights into the mechanisms and causes of product and material defects and failures.

When a structural element of a product is broken or has defects, that can cause product failure. Cracks, pores, or wrong shapes are the types of structural failure.
In this episode, we will define what structural failure is and discuss how it manifests in materials and designed parts in the form of cracks, pores, etc. We will also review where failure analysis is used in various industries and research areas and what could go wrong if it is neglected. This episode explores examples of structural failure analysis using X-ray CT.

Even if nothing is clearly broken, some parts in a product can be slightly misaligned or deteriorate in its function. These problems can eventually cause product failure. The shorting of a circuit and deteriorated battery life are examples of such functional failure.
In this episode, we will define what a functional failure is and review how you can use X-ray CT to characterize various defects that can cause diminished or loss of function. Oftentimes, a material or product will exhibit diminished or partial loss of function before it becomes inoperative. Understanding why and how these initial problems occur is as important as understanding complete failure because it helps us understand the mechanisms of failures and improve manufacturing and production processes. This episode will explore examples of functional failure analysis using X-ray CT.