How Not to Perform a Failure Analysis

“HOW NOT TO PERFORM A FAILURE ANALYSIS”

By:  Randy Nixon and Mark Schilling – Corrosion Probe, Inc.

Abstract

Too often, coating failure analysts ignore the evidence in front of them and excessively utilize analytical testing simply because it is available to them.  This tendency to rely on high tech test data to find a conclusion that supports a biased point of view about the cause of the failure is the wrong way to approach failure analyses.  Frequently, this overuse of analytical methods complicates logical and accurate failure analysis work.  This paper discusses a classic example where the facts surrounding the failure of a lining were ignored and undue reliance was placed on laboratory analysis.  This “blind faith” in analytical data without a sound causal theory caused the respective analysts to disregard or overlook the obvious.  This example is presented by demonstrating the divergent paths between what the facts showed and how the analyses missed the mark.