Failure Investigation & Failure Analysis

The Intertek MSG Microscopy Team

The Intertek microscopy team, a group of ex-ICI polymer scientists, operates a worldwide material and component Failure Investigation service with a renowned track record stretching back over fifty years. The team focuses on Failure Investigation of polymers, blends, compounds, laminates, advanced materials and, particularly, the end-user products manufactured from these materials. One of the key factors in the team's success is their intimate knowledge of raw material production processes, polymerisation technology, moulding processes and end-user applications that vary from simple packaging films through consumer goods to advanced aerospace materials.

Failure Investigation involving fracture and failure of materials such as fibres, films and membranes, polymers, engineering plastics, composites, coatings and paints all represent the heartland of the Intertek MSG microscopy team’s competency. And have we seen expensive problems!  Design faults, moulding issues, stress, overload, degradation, unintentional service conditions, misuse and even sabotage have all passed under the team’s microscopes,one common theme bding that no-one ever wants to admit liability. This is where independent failure investigation adds huge value to our clients – especially when backed by such a trusted and well-respected team with a track record second to none.

For over 25 years John Dale (Microscopy Team Leader) has worked with the processors and end users of engineering plastics demonstrating on countless occasions the value of understanding the root causes of polymer component failure from both technical and financial perspectives. The team around John is World Class and, being highly customer-focused, recognises that Failure Investigation is one of the most challenging and disturbing "business critical" events that clients entrust into our hands. Over the years the failure investigation team has come to truly understand what it feels like to see a quality system fail, have parts return from dissatisfied customers and experience the subsequent panic arising from the fact that you just don't know what the business impact of all this is going to be.  Be assured, when polymer materials or components snap, crackle or pop,  it is the Intertek MSG Microscopy Team that you want right at your side.

Successes
Because of the highly sensitive nature of failure analysis the team obviously cannot be too specific in describing customers’ cases

The determination of the many causes of environmental stress crazing in blow-moulded PET bottles failing catastrophically on supermarket shelves.

The root cause of cam belt gear failure (leading to extensive engine damage in many new vehicles) traced to an act of deliberate sabotage at a specific point in the component’s supply chain.

A large number of nylon components failed on mechanical testing - proved to be the fault of the raw material supplier who had cross-contaminated the nylon with other moulding materials.

Returns of a broken plastic child-care device from the field were found to have resulted from microscopic performance detractors - the consequence of an inadequate design process by a sub-contractor.

Yogurt cartons fracturing in use were found to have shear orientation of the carton wall leading to brittle failure – the result of a temperature band being out of specification on a supplier’s moulding machine.

Successes
Military rifle sights produced from a glass filled engineering plastic were fracturing when troops dropped the weapons. Failure investigation resulted in the supplier being advised on improvements to his mould and moulding process.

A hose clip in an aerospace application failed regularly when assembled on the production line. Fracture analysis indicated a performance detractor in the design of the component and resulted in a recall.

A high reject rate during the manufacture of plastic baths was evaluated and led to a full contamination audit of the supply chain as the breakages were mainly due to particulate contamination of the polymer.

Surface defects noted on electrical components returned from the field were identified as being entrapment of volatiles due to a sub-contractor who had failed to dry the polymer before moulding.

Fittings for a domestic appliance were failing in service.  Microscopic failure investigation revealed that consumer misuse of the part was leading to UV-induced degradation of the material.