ISO 17025 UKAS accredited

Over three decades of experience

Material Consultancy | SureScreen Materials

Failure investigation

By combining in-house materials testing and analysis with expert interpretation, we are able to quickly and effectively assist clients with the information required to get to the root cause of materials failures.

Covering a wide variety of investigations. Examples would be common materials such as steel, cast iron, extruded and cast aluminium, through to materials used in more aggressive environments such as nickel super alloys and titanium alloys. We also cover non-metallic materials such as polymers, elastomers and ceramics in a range of forms. Within metallurgy, an investigation could cover grain size, inclusion type and count along with deleterious effects such as porosity and segregation. Within polymers it could cover assessing the types of material used, fillers, distribution of fibre reinforcing etc.

Expert Consultancy

We offer an initial consultation in-person, online or on the phone to fully understand your requirements prior to providing a quote. Our laboratory and office is situated in Derby in the midlands and many of our clients visit for a coffee and a discussion regarding the required work at our Georgian house premises. The expert leading the investigation will review various options with you and discuss the investigation background, required turnaround time, reporting style etc. to ensure you as the client gets the exact service you require.

Point at a component that has failed | SureScreen Materials

Technical Analysis

We have a range of in-house materials analysis and testing instruments that can provide results to support an investigation. These include EDS (analytical function of the SEM), FTIR (characterisation of organic and IR absorbing materials), XRF (onsite chemical analysis), GCMS / HPLC (analytical chemistry) and a range of hardness testers including an automated microhardness tester.

In-depth Reporting

For investigations, we offer two report types: portrait (traditional style) and presentation-style. These are suited for different usages and the most appropriate is usually dependent on the intent of the report. For the most thorough and in-depth investigations that could be used in court, portrait-style reporting would be recommended. Presentation-style reports are image dense and provide the findings of investigations with clear diagrams and supporting text. These reports can be ideal for internal use as they can often provide information in a more clear and concise manner.

Example Reports

Full Investigation Report | Cover Page | SureScreen Materials

Portrait (traditional style) Report

Portrait, traditional style report with in-depth discussion, conclusions and supporting referenced figures at the end. Recommended for the most thorough and in-depth investigations that could be used in court.

Introduction

This section outlines the background of the investigation, any relevant information provided and what laboratory techniques will be performed on the sample.

Examination

This section documents the findings of the visual examination along with the findings of examinations using our various microscopes.

Test Results

The results of the tests and analyses conducted will be provided with any relevant standards.

Discussion

Interpretation of the results and examinations with expert opinion and relation of the findings of the report to the larger context of the assembly or system.

Conclusion

Concise conclusions which provide statements of facts and the key findings of the investigation.

Figures

Brings together the findings of the examinations and test results and discusses implications with regards to the issue as well as suggestions as to how to prevent the issues in the future.

Presentation Report | Examination | SureScreen Materials

Presentation-style Report

For investigations requiring predominantly diagrams and images along with concise text; we can report in a presentation style report. Ideal for internal use as they can often provide information in a more clear and concise manner

Example Investigations

Stress corrosion cracking of a copper alloy component

AlSi7Mg0.55 die cast aluminium exposed to cyclical stresses in a sea water environment. Heat treatment history unknown. Examination of the fracture surface revealed fractographic ‘beach markings’ highlighting the origin of progressive crack growth. The microstructure consisted of alpha phase and silicon eutectic with isolated intermetallic phases consistent with the alloy grade. Intergranular cracking and corrosion attack was observed at the surface, consistent with Stress Corrosion Cracking (SCC) preferential to the alpha phase. SCC was a result of exposure to a chloride rich environment combined with service stresses. SCC then provided a stress raiser for fatigue crack initiation and propagation resulting in fracture.

Stress Corrosion Cracking of Aluminium Casting_Fract init x200

Stress Corrosion Cracking of Aluminium Casting_inner surf corr x500

Bearing rolling contact fatigue

A rolling element bearing exhibiting rolling contact fatigue (RCF) spalling of the working surfaces. RCF was observed on the inside and outside race as well as the bearings. Hardness surveys revealed the races to be of the same hardness as the rolling elements; maximum fatigue life is achieved when the rolling element is approximately one to two points (Rockwell C) harder than the races. The bearings were later established to be counterfeit.