Failure analysis and Prevention

By Prof. D K Dwivedi | IIT Roorkee

Learners enrolled: 2445

The course content is designed to systematic understanding on various aspects related with failure such as fundamental sources of failure of mechanical components, industrial engineering tools relevant to failure and failure analysis, general procedure of failure analysis through sample collection, preparation and preservation, testing, macro and microscopic observation of fracture, mode of fracture, metallographic procedure and image analysis, use of fracture mechanics and fracture toughness principles in failure analysis and analysis findings and report/recommendation writing. Presentation will include case studies to communicate concepts and procedures effectively. Case studies will be taken up from failure analysis of weld joints in different sectors.

INTENDED AUDIENCE :UG and PG Student, Research Scholar & Practicing Engineers

PRE-REQUISITES : Nil

INDUSTRY SUPPORT :Heavy engineering and pressure vessel industry, power plants

Summary

Course Status :	Completed
Course Type :	Elective
Duration :	8 weeks
Category :	Mechanical Engineering
Credit Points :	2
Level :	Undergraduate/Postgraduate
Start Date :	24 Feb 2020
End Date :	17 Apr 2020
Enrollment Ends :	24 Feb 2020
Exam Date :	26 Apr 2020 IST

Note: This exam date is subjected to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week1:

1. Introduction: Need and scope of failure analysis and prevention

2.Introduction: Engineering disasters and understanding failures

3.Fundamental sources of failures: Deficient design I

4.Fundamental sources of failures: Deficient design II

5. Fundamentalsources of failures: Deficient design III and upgrading of a part

Week2:

1.Fundamental sources of failures: Imperfections in base metals

2.Fundamental sources of failures: Improper Manufacturing I

3.Fundamental sources of failures: Improper Manufacturing II

4.Fundamental sources of failures: Improper Manufacturing III

5.Fundamental sources of failures: Improper Manufacturing IV and improper service conditions

Week3:

1. Fundamental sources of failures: Poor assembly, service andmaintenance

2.Industrial engineering tools for failure analysis:Pareto diagram

3.Industrial engineering tools for failure analysis:Fishbone diagram and FMEA

4.Industrial engineering tools for

failure analysis: FMEA

5.Industrial engineering tools for failure analysis: Fault tree analysis

Week4:

1.Industrial engineering tools for failure analysis: Reliability-I

2.Industrial engineering tools for failure analysis: Reliability-II

3.General procedure of failure analysis: Steps

4.General procedure of failure analysis: Background information collection

5.General procedure of failure analysis: Preliminary examination

Week5:

1.General procedure of failure analysis: NDT for failure analysis

2.General procedure of failure analysis: Destructive testing

3.General procedure of failure analysis: DT, selection, preservation, cleaning & sectioning of samples

4.General procedure of failure analysis: Macroscopy of fracture surfaces-I

5.General procedure of failure analysis: Macroscopy of fracture surfaces-II

Week6:

1.General procedure of failure analysis: Macroscopy of fracture surfaces-III

2.General procedure of failure analysis: Macroscopy of fracture surfaces-IV

3.General procedure of failure analysis: Microscopy of fracture surfaces

4.General procedure of failure analysis: Metallography of failed components

5.General procedureof failure analysis: Determination of type of fracture I

Week7:

1.General procedure of failure analysis: Determination of type of fracture II

2.General procedure of failure analysis: Determination of type of fracture III and chemical analysis

3.General procedure of failure analysis: Application of fracture mechanics I

4.General procedure of failure analysis: Application of fracture mechanics II

5.General procedure of failure analysis: Simulated test and analysisof evidences/results

Week8:

1.General procedure of failure analysis: Questions for analysis

2.General procedure of failure analysis: Reporting failure analysis and failure analysis of welded joint

3.General procedure of failure analysis: Failure analysis of weld joint

4.General procedure of failure analysis: Examples of failure analysis

5.General procedure of failure analysis: Embrittlement of steels

Books and references

Becker et al. Failure analysis and prevention, ASM Handbook (2002) Hutching et al. Failure analysis, ASM International (1981) Besterfield et al. Total quality management, Pearson (2002)Engineering failure analysis, Journal, Elsevier Failure analysisand prevention, Journal, Springer .

Instructor bio

Prof. D K Dwivedi

IIT Roorkee

D K Dwivedi obtained BE (mechanical engineering), in 1993 from GEC Rewa, ME (welding engineering) from Univ. of Roorkee in 1997 and PhD in Met. Engineering from MNIT, Jaipur in 2003. He has about 9 years teaching experience at NIT Hamirpur and 14 years at IIT Roorkee in subjects related with manufacturing at UG level and welding engineering related subjects at PG level. He has published more than 120 research papers in SCI/SCIE indexed journals and undertaken 20 sponsored research and 50 industrial consultancy projects. He has authored two books entitled Production and Properties of Cast Al-Si Alloys with New Age International, New Delhi (2013) and Surface Engineering with Springer, New Delhi (2018).

Course certificate

• The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
• The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
• Date and Time of Exams: 26th April 2020, Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
• Registration url: Announcements will be made when the registration form is open for registrations.
• The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
• Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE:
• Average assignment score = 25% of average of best 6 assignments out of the total 8 assignments given in the course.
• Exam score = 75% of the proctored certification exam score out of 100
• Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75.
• If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.
• Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Roorkee. It will be e-verifiable at nptel.ac.in/noc.
• Only the e-certificate will be made available. Hard copies will not be dispatched.

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