This course introduces the fundamental concepts of the failure analysis methods and tools of engineering components. Topics include analysis of broken components by macroscopic and microscopic observation, review of common experimental methods used in failure analysis, specific description of failure mechanisms of composite, metallic, ceramics, and polymeric materials. Throughout the classes, students are expected to gain an understanding of these subjects and how they are applied in industrial applications.

Learning outcomes:
By the end of the course, students will be able to:
Structure a failure investigation using a hypothesis–evidence–decision workflow.
Distinguish brittle/ductile, overload/fatigue, environment-assisted, and process-induced failures from fractographic and contextual evidence.
Apply core fracture mechanics concepts (stress concentration, LEFM basics, crack growth logic) at an engineering level.
Select fit-for-purpose tests/standards and recognize common pitfalls and confounders.
Document microscopy and fractography correctly (scale, orientation, ROI logic, traceability).
Produce a concise, defensible failure analysis report with corrective/preventive actions.

Teaching & learning methods

Short lectures + worked case studies (industry-style)

In-class microscopy/fractography “micro-labs” (stereo/optical)

At least two SEM-oriented session (demo/rotation or instructor-led image set)

Team-based “case file” project (evidence pack → report → defense)

Resources

Lecture notes (via SUCourse)

Prepared course case studies (distributed during the semester)

Selected published/public case studies (e.g., Titanic, OceanGate)

Key technical references :

Greenhalgh, E. S. (ed.), Failure Analysis and Fractography of Polymer Composites (Woodhead/Elsevier).

Hayes, M. D.; Edwards, D. B.; Shah, A. R., Fractography in Failure Analysis of Polymers, 2nd ed. (Elsevier, 2024).

Quinn, G. D., NIST Recommended Practice Guide: Fractography of Ceramics and Glasses, 3rd ed. (NIST SP 960-16e3, 2020).

ASM Handbook, Volume 12: Fractography (ASM International) — metals-focused fractography reference.