Welding and Joining Failure Analysis Methodology and Techniques

The complexity of welding presents numerous opportunities for failure analysis. As a result, a robust methodology is necessary to effectively identify, classify, and mitigate failures. This proposed approach is based on seven key steps: 1) Collecting background information by asking the right questions, 2) Identifying potential contributors to failures, 3) Reviewing technical resources, 4) Defining analysis techniques, 5) Testing, 6) Evaluating results, and 7) Implementing changes to eliminate failures.

This presentation showcases multiple examples demonstrating how this methodology has been successfully executed to determine and address root causes of critical welding failures such as liquid metal embrittlement, solidification cracking, weld contamination, and hydrogen-induced cracking. The implementation of this approach has enabled the welding industry to effectively eliminate numerous end-user failures.