King Professional Engineering, Inc.


Failure Analysis is the process of collecting and analyzing information to determine the cause of a device or system “failure.” “Failure” is a technical term used in mechanical engineering referring to the point when a device becomes inoperable, not able to function satisfactorily, or degrades to the point where it is unsafe or unreliable. This could mean that the device broke (fractured), burst, wore out, melted, burned, corroded, bent, flexed excessively, etc. Causes of these failures might include: incorrect design or material selection; material or fabrication flaws; problems in processing; assembly; reworking and reassembly; inadequate quality control, inspection, or testing; improper operation or loading; faulty maintenance, unexpected temperature variation; or chemical exposure. As the term indicates, a failure analysis typically seeks to identify the origin and cause of the mechanical failure. The failure analysis process pulls together a broad variety of information through the use of an array of analysis procedures. King Professional Engineering, Inc., conducts failure analyses for incidents involving mechanical engineering devices, equipment and mechanisms.

Failure Analysis Results

Forensic mechanical engineering incident investigations frequently require a failure analysis conducted by a qualified mechanical engineering expert as a part of assessing the causes of an accident or incident involving mechanical devices. King Professional Engineering, Inc., provides failure analysis or root-cause analysis as a part of litigation support and expert witness services to the legal profession and insurance industry.

Mechanical Engineering Expert


What types of results might a Failure Analysis show? Results from a thorough failure analysis typically indicate the underlying origin, or “root cause(s),” that produced the device’s failure, including, for example:


  1. •Design Defect(s)—Examples of design defects might be overly high stresses at critical location(s), improper construction material selection, improper component selection, part not sufficiently stiff (or too stiff), etc.

  2. •Manufacturing Defect(s)—Substitution of material or component not called for in design, component dimensions not manufactured according to specifications, damage during manufacturing, packaging, and/or transporting processes.

  3. •Operator Error—Mishandling by operator: overloading, improper procedure, overheating, etc.

  4. •Procedural Inadequacies—Improper or inadequate maintenance, operator training, instructions, warnings, etc. 

Failure Analysis: What is it?

Depending upon the specifics of the case, investigative methods such as the following may be used:

  1. •Preservation of Evidence—throughout the process of investigation, care is exercised to ensure all evidence is preserved. No destructive actions are to be taken without the knowledge and consent of all parties.

  2. •Documentation of the Scene—photos, surveys, mapping, measurements, scale drawings, etc.

  3. •Detailed Observation—examination with optical and/or electron microscopes, macro-photography, fractography, examination and photography of fracture surfaces, etc.

  4. •Metallurgical Testing—testing the material(s) involved for strength, hardness, metal chemistry, microstructure, etc.

  5. •Environmental Considerations—testing for contaminants, corrosives, etc.

  6. •Engineering Calculations—stress analysis, stability calculations, vapor flammability calculations, finite element analysis, etc.

  7. •Evaluation of Device’s Engineering—design, operating procedures, maintenance, service, and modification history, etc.

  8. •Specialized Testing—customized testing of systems and components to assess functionality, operability, witness accounts, and failure hypotheses.

  9. •Evaluation of Witness Accounts—review and analysis of witness accounts, testimony, investigation reports, etc.

  10. •Creation & Analysis of 3D Computer Models--Three dimensional, or “3D” computer models often reveal failure mechanisms as well as provide excellent illustrations for facilitating communications.

King Professional Engineering, Inc.


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-Failure Analysis-Accident Investigation-Forensic-Expert Witness-Mechanical Engineering Expert,

Forensic Engineering Expert, Forensic Analysis Expert-Root-Cause Analysis, Products Liability Expert-

Houston Office: 4321 Kingwood Dr., Suite 26 Kingwood TX 77325

Copyright 2012 King Professional Engineering, Inc.

Thorough Investigations-Clear Communications

For our clients’ needs, we focus on high-quality custom-designed investigations and forensic mechanical engineering analysis with special emphasis on providing down-to-earth communication and clear presentation that you can use to resolve complex issues and communicate with others

                                                                            —our goal is to make the complex comprehensible.

Randall K. King, Ph.D., P.E.,

Dr. King is a licensed professional engineer and expert witness, who holds a Ph.D. in mechanical engineering. He has over 33 years professional experience in mechanical engineering, product design, research & development, forensic investigation, and litigation support. Additionally, Dr. King holds 21 patents. More...

713.609.9092

©2012 King Professional Engineering, Inc.

713.609.9092