Analysis of Machine-part Failures (FSI-GA0)

The objective of this course is to familiarize students with the issues of material degradation and with the methodology for assessing the causes of mechanical component failures, at a level that enables them to address such problems independently or in collaboration with specialized laboratories.

The course will train students to regard engineering materials as chemically and structurally heterogeneous systems whose performance under real operating conditions is significantly influenced by these heterogeneities. The presented methodology for identifying failure causes enables students to analyze problems in relation to the interaction between material heterogeneity, loading conditions, and environmental influences.

Fundamental knowledge of materials engineering at the level of introductory bachelor-level courses is required. Students should have a solid understanding of limit states, particularly in the areas of mechanical testing and failure mechanisms. A general familiarity with strength and stress analysis of mechanical components is also expected.

Analysis of Machine-Part Failures

This course provides students with a fundamental understanding of the primary mechanisms of manufacturing and operational degradation affecting metallic materials commonly used in mechanical engineering applications. The knowledge gained will enable students to more accurately assess material strength, optimize the utilization of engineering materials, and competently identify and evaluate the underlying causes of component failures.

The course further introduces methodologies for failure analysis of mechanical components, supported by case studies derived from both technical literature and the teacher's professional experience in various engineering sectors, including automotive and aerospace systems, power generation equipment, pressure vessels, and industrial machinery.

A key component of the course is the review and application of widely used experimental techniques essential for failure investigations, such as chemical and microchemical analysis, metallography, and fractography.

Successful completion of the course is based on an individual student's presentation prepared in advance, followed by a discussion with classmates and the instructor on the presented topic. Students select their presentation topics from the provided handbooks, conference proceedings, or scholarly journals (in English or German).

The final grade is assigned according to the ECTS grading scale and reflects both the quality of the presentation and the student’s demonstrated mastery of the subject matter, as evidenced by their responses to questions.

The course covers the following thematic areas:

1. Introduction and Scope of the Course
Failures of structural components. Methodology of failure analysis: assessment procedures, required technical expertise, experimental methods, and the structure of the final analysis report.
2. Experimental Methods
Light microscopy, SEM + EDS, EBSD, TEM — including a visit to the IMSE laboratories, and a visit to the failure analysis workspace and archive of failure analyses.
3. Fractography of Metallic Materials
Principles, interpretation of fracture surfaces, and their relevance to determining failure causes.
4. Manufacturing-Related Degradation in Metallic Materials
(metallurgical issues, non-metallic inclusions, macrosegregation, microsegregation, and weld defects)
5. Operational Degradation in Metallic Materials
(hydrogen embrittlement, wear mechanisms, fatigue damage, corrosion, stress corrosion cracking, and corrosion fatigue).