ADVANCED MATERIALS & PROCESSES | NOVEMBER/DECEMBER 2025 24 Understanding that a properly conducted failure investigation is a process, not a singular event, is essential to the success of the investigation. An effective failure investigation is comprised of two key elements: 1) a systematic method; and 2) a team effort. This is the first article in a threepart series developed to provide the reader with an understanding of what comprises an effective failure investigation. Specifically, this series will provide an understanding of: • The purpose and key elements of a failure investigation • The definition and sequence of a materials failure • A detailed model for a systematic failure investigation Failure investigations can range from relatively small and simple to extremely large and complex. (See examples in the two sidebars.) Regardless of the scale of the investigation, the principles and methodology should remain the same and differ only with the level and divisions of execution. Before examining the individual elements of a failure investigation, this article will start by identifying the purpose of the process and what it is designed to accomplish. At first glance, the investigative process and its goals would seem fairly straightforward. The obvious objective or goal would be to determine “what caused the failure.” FAILURE INVESTIGATIONS: A SYSTEMATIC PROBLEMSOLVING PROCESS, PART I The first part in an article series introduces a systematic, team-based approach to failure investigations that goes beyond identifying what failed and includes determining the root causes and applying corrective action. Jeffrey L. Hess, Fort Wayne, Indiana investigation, accident investigation, scientific investigation, or any other formal investigation, a systematic methodology and well executed plan is always required if the investigation is to be a success. There are many problem solving and investigative methods utilized by various industries, and caution needs to be exercised to make sure the investigative method utilized is complementary to the investigation’s purpose and goals. The same problem- solving methodology is not recommended for both an accident investigation and a scientific investigation. Each failure investigation requires a unique problem-solving process and thus needs a unique and properly tailored approach. This leads to the need for an understanding of the true purpose of That is where a certain degree of confusion regarding the goal of a failure investigation occurs and requires clarification. As will be presented in this and following articles, the “what” of the failure is simply the identification of the failure mode and the actual beginning of the process. The complete investigative process effectively defines not only the “what” (failure mode), but also the “how” (failure mechanism), and most importantly the “why,” (failure source) or the true root cause (TRC) of the failure event as illustrated in Fig. 1. A SYSTEMATIC METHOD IS REQUIRED Any properly conducted investigative process requires a systematic method to be effective. Whether it is a failure investigation, crime scene Fig. 1 — Progression of a materials failure investigation.
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