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ME
466
Failure Analysis
Introduction to the field of failure analysis including real-world practical investigations and solutions to actual failure problems with technical products, equipment and systems, product liability issues, failure prevention techniques, remedial design, engineering ethics, the engineer as an expert witness.
Prerequisites:
0630351
0630466
(3-0-3)

ME 466 - FAILURE ANALYSIS

(Elective)

Description : ME 466: Failure Analysis (3,0,3).

(Prerequisite: ME 351)

Introduction to the field of failure analysis in mechanical components including real-world practical investigations and solutions to actual failure cases. Product liability issues, failure prevention techniques, remedial design, engineering, the engineer as an expert witness.

Text Book:

Failure Analysis: Fundamentals and Applications in Mechanical Components, Jose Luis Otegui, Springer; 2014 Edition.

References:

  1. Practical Engineering Failure Analysis, Hani M. Tawancy, Anwar Ul-Hamid, CRC Press, 1st Ed., 2004
  2. Forensic Materials Engineering: Case Studies by Peter Lewis et al, CRC Press 2003.
  3. Failure of materials in Mechanical Design: Analysis, Prediction, Prevention, by J.A. Collins, 2nd Edition, Wiley, 1993.
  4. Failure Analysis Case Studies II, D.R.H. Jones, Pergamon, 2001.
  5. Practical Engineering Failure Analysis, Hani M. Tawancy, Anwar Ul-Hamid, Nureddin M. Abbas, Marcel Dekker, 2004.
  6. Machinery Failure Analysis Handbook: Sustain Your Operations and Maximize Uptime, Luiz Octavio Amaral Affonso, Gulf Publishing Company, 2006.
  7. Root Cause Failure Analysis, R. Keith Mobley, Butterworth-Heinemann, 2011.
  8. Failure Analysis of Engineering Structures: Methodology and Case Histories, V. Ramachandran, ASM International, 2005.

Coordinator:

Solid Mechanics and Design (SMD) TAG

Prerequisites by Topics:

  1. Analysis and Design of Mechanical Components.
  2. Failure Theories

Course Learning Objectives[^1]:

  1. To convey a sense of real world engineering practice through examination of case studies related to equipment analysis and system design failures and accidents caused by errors and omissions in the engineering process (1,2,4,6,7)
  2. To introduce methodology of failure analysis from initial on-site investigation to final report and possible testimony as an expert witness (1,2,3,4,5,6,7)

Topics:

  1. Introduction
  2. Tools for Preliminary Analysis of a Mechanical Failure
  3. Tools for the Microscopic Analysis of a Mechanical Failure
  4. Mechanisms of Damage and Failure
  5. Damage Resistance Tests of Materials
  6. Damage and Failure Mechanisms in Machinery
  7. Consequences of a Failure Analysis

Suggested Evaluation Methods:

  1. Homework
  2. Case-study reviews
  3. Failure projects with oral and written report
  4. Exams

Course Learning Outcomes:

Upon completion of this course students will be able to:

Objective 1

  1. recognize the importance of safe engineering design based on extensive case history reviews of successful and unsuccessful designs
  2. recognize the importance of using codes and standards in the development of a safe engineering design
  3. recognize the ethical, societal, and environmental issues associated with the engineering profession

Objective 2

  1. develop a methodology which allows for the assessment of failures and determine their causes
  2. develop quantitative methods for the assessment of hazards and risks
  3. reconstruct accidents based on failure investigations and report the results as an expert witness
  4. suggest remedial actions to incorporate safe design in the initial design or in retrofitting existing products

Course Classification

Student Outcomes Level Relevant Activities
H, M, L
1. An ability to identify, formulate, and solve complex engineering problems by applying principles of engineering, science, and mathematics. H Use of mathematics, physics, chemistry and engineering science in failure analysis. Investigation of causes of failure.
2. An ability to apply engineering design to produce solutions that meet specified needs with consideration of public health, safety, and welfare, as well as global, cultural, social, environmental, and economic factors. M Design characteristics of various types of products. Role of failure theories in safe design.
3. An ability to communicate effectively with a range of audiences. M Project report. Case studies reports.
4. An ability to recognize ethical and professional responsibilities in engineering situations and make informed judgments, which must consider the impact of engineering solutions in global, economic, environmental, and societal contexts. H Ethical responsibility in the design of safe product, in quality control, and in reporting. Importance of human factors, safety, and reliability in the design of products. Effect of new technologies on the environment and on the natural resources
5. An ability to function effectively on a team whose members together provide leadership, create a collaborative and inclusive environment, establish goals, plan tasks, and meet objectives. M Teamwork in projects and in case studies.
6. An ability to develop and conduct appropriate experimentation, analyze and interpret data, and use engineering judgment to draw conclusions. M Analysis and interpretation of reports and of inspection data. Use of modern instrumentation and of computer in measurement, analysis and interpretation of data.
7. An ability to acquire and apply new knowledge as needed, using appropriate learning strategies. M Reading of references, codes, standards, professional periodicals and handbooks.

[^1]: Numbers in parentheses refer to the student outcomes