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Failure Analysis:

JFP Technical Services, Inc. has over 40 years of experience in the performance of failure analysis on many different products, components, and processes, made from all types of materials, which have come from many different industries and businesses.

Failure analysis is the general term used for the combination of methods used in determining why a product, a process, or other actions did not perform as expected, resulting in injury or death, a loss of time and money, a customer rejection, loss of material, a malfunction, all possibly leading to a loss of reputation. Failures can be very simple or very complex, and can be due to latent defects. There are many causes of failures ranging from: overloads, brittleness, ductility, fatigue, misuse, wear, corrosion, environmental exposure, poor design, incorrect or poor processing, accidents, damage, oversight, material mix-up, lack of training, design error, sabotage, and many other causes.

There are many analysis methods that can be used when performing a failure analysis including: metallurgical analysis, visual inspection, forensics, reconstruction, simulation, material analysis, dimensional inspection, scanning electron microscopy (SEM) analysis, fracture surface analysis, chemical analysis, residue analysis, fiber analysis, troubleshooting, hardness testing, and verification of any required or specified quality characteristics. The analysis may require a combination of test methods and techniques to find the root cause of the failure, which is where the experience of JFP Technical Services can be most valuable by providing a detailed analysis that leads to the conclusion(s) about the cause of the failure.

The sooner a failure analysis can begin, the sooner the result and conclusions may be available. This is because the sooner the failure analysis begins there are more details and more accurate information about the facts surrounding the failure that are available and fresh. Documentary photographs should be taken showing the surrounding conditions and effects of the failure. Material analysis should be performed before any degradation occurs that may destroy key evidence or the fracture surfaces. The main reason to begin the analysis as soon as possible is to identify the cause, which can be used to determine if there are other potential latent failures, have time to develop test methods to find other similar defects, and take steps to prevent similar failures from occurring that may lead to additional damages. If you should have a product or equipment failure, contact JFP Technical Services as soon as possible, so we can start working with you on the failure analysis.

We can you help collect important evidence and observations on-site, if needed.

We can help you gather the background information needed for a full and complete failure analysis.

We can observe production processes or operation of a product to identify possible problems.

The cost of a failure analysis will vary based on the types of testing methods used and time needed, but an Estimated Cost can be provided once the items to be analyzed have been seen. We also perform failure analysis using “Not to Exceed Cost”, requiring approval to proceed beyond prior cost limitations.

Product Design Review:

JFP Technical Services, Inc. has over 40 years of experience in the performance of evaluating products for possible failures. We can perform the following in evaluating a product:

We can observe production and assembly processes or the operation of a product to identify possible problems.

We can look into the materials and the processes being specified to control the material’s properties (E.g.: heattreating, plating, welding, etc…).

We can perform load testing of the product to determine weak points and possible failure modes.

We can review prints for possible areas of design concern, proper material and process specification callouts, and to make sure specifications are clear and accurate.

We can perform comparison testing of materials, products, vendors, or processes.

We can perform reverse engineering of the product material requirements.

We do not perform dimensional measurement or electrical measurement evaluations.

Failure Analysis & Product Design Review Specifications

General Capabilities:


Nondestructive Testing
Load Testing
Metallurgical analysis

Types of Analysis:

Metallurgical Analysis
Visual Inspection
Material Analysis
Dimensional Inspection
Scanning Electron Microscopy (SEM) Analysis
Fracture Surface Analysis

Chemical Analysis
Corrosion Investigation
Residue Analysis
Fiber Analysis
Hardness Testing
Surface Roughness
Requirement Verification

Assembly & Component Failure Analysis:

Adhesive, Plating and Coating
Automotive, Truck and Aerospace
Circuit Boards and Solid State Electronics
Consumer Products and Equipment
Fastener, Bearing and Gear
Medical Products

Metals – Ferrous and Nonferrous
Plastic and Rubber Products
Tool and Die
Tubular Products
Weldment, Casting and Forging

Process Troubleshooting:

Chemical Reactors and Mills
Forging and Cold Forming
Heat Treating – Annealing, Hardening, Normalizing

Machining – Turning, Milling, Grinding, Polishing
Roll Forming and Tube Mills

Failure Analyses Performed:

Acid Exposure
Adhesives and Bonding Issues
Air Conditioning Components
Airplane Components
Alkaline Exposures
Assembly Problems
Automotive Components
Braze Joints
Brittle Failures
Contamination Issues
Castings: Steel, Iron, Aluminum, Copper, Zinc, Brass, Lead and Other Metals
Cooling Towers
Connectors and Connector Pins
Construction Equipment
Corrosion: Marine, Environmental, General Exposure, Rust
Crimps, Crimping, and Crimped Connections
Dental Devices, Equipment and Tools
Drive system components: Belts, Sheaves, Chains, Sprockets
Ductile Failures
EDM Recast Layer and Surface Finishes
Electric Motors
Electrical Contacts
Engine Components
Fasteners, Bolts, Nuts, and Screws
Fire Damage
Food Processing Equipment
Forming and Bending
Foundry Equipment
Furnace and Heating Components
Furniture and Chairs
Gas Lines
General Manufacturing
Heat Treating
Hoists and Cranes
Hydraulic and Pneumatic Cylinders
Hydraulic and Pneumatic Hose and Fittings
Hydrogen Embrittlement
Insurance Claims
Injection Molding Issues
Jet Engine Components

Lifting equipment
Lubrication and Lubricants
Material Issues, Raw or Base Material
Machining Tools
Machining, Grinding, Turning
Medical Devices and Equipment
Mining Equipment
Motorcycle Components
Musical Instruments
Naval Equipment
Non-Destructive Testing (NDT) Defects
Nuclear Equipment
Off-Road Vehicle Components
Oilfield Equipment
Optical Devices and Equipment
Paint and Painting
Plasma Cutting
Plastic Molded Components
Plating and Coatings
Pressure Vessels
Printed Circuit Boards
Residues and Debris
Rubber Components
Solar Power Components
Solder Joints and Soldering
Surface Finishes
Surface Mount Components
Threads and Threaded Holes
Tools and Dies
Tubing and Pipe
Truck Components
Utility Equipment
UV Exposure
Warranty Claims
Welds and Weldments
Welding: GTAW, GTAW, TIG, SAW, Friction, Laser, Electron Beam, Resistance Spot, Ultrasonic
Wind Power Components
X-ray Equipment
Yield Failures
And Many More….