Failure Analysis Solutions – Metallurgical, Mechanical & Root Cause Testing
Failure Analysis Solutions – Metallurgical, Mechanical & Root Cause Testing
Expert Failure Analysis for Metal, Polymer, and Industrial Components.
QAI Laboratories delivers expert failure analysis for metal, polymer, and composite components. With thousands of investigations completed, our ISO/IEC 17025-accredited lab supports manufacturers, engineers, and quality teams through customized materials testing and root cause analysis.
From fatigue fractures and weld defects to contamination and heat treat issues, QAI provides clear, actionable insights to resolve urgent problems and prevent future ones. Whether you’re facing a product recall, production line issue, or customer complaint, we bring deep technical expertise and real engineering support to every project.
What is Failure Analysis?
Failure analysis is the systematic process of determining why a component, material, or product did not perform as expected. It identifies the root cause of failure—whether mechanical, chemical, thermal, or environmental—to help prevent recurrence and improve long-term reliability.
At QAI, our failure analysis approach combines:
We assess physical evidence, review service conditions and design specifications, and provide expert interpretations backed by hands-on engineering experience.
Our Process Includes:
Engineering consultation and failure prevention planning
Sample preparation and documentation
SEM/EDS analysis and imaging
Metallography and microstructure review
Mechanical testing (tensile, impact, hardness)
Surface evaluation and contamination detection
Root cause identification and reporting
New vendor part analysis with materials data and comparison
Why is Failure Analysis Important?
Understanding why a part failed is essential for improving product reliability, managing liability, and maintaining production continuity. QAI’s expert failure analysis helps you prevent repeat issues, address customer concerns, meet industry requirements, and protect your brand reputation. With rapid turnaround and detailed reporting, we help you respond quickly when failure matters most.
Why Choose QAI for Failure Analysis?
- Thousands of failure investigations completed
- ISO/IEC 17025-accredited lab with six specialty areas
- Full in-house SEM/EDS, mechanical, chemical, and metallurgical testing
- Fast response for urgent and emergency testing needs
- Clear, actionable reports for both technical and non-technical audiences
- Trusted by major manufacturers in aerospace, automotive, energy, and more
- Trusted by manufacturers in aerospace, automotive, medical, energy, and industrial sectors for failure prevention, vendor qualification, and part validation
Beyond Failure Analysis
In addition to root cause investigations, QAI supports:
- New part validation
- Vendor product comparisons
- Material verification and compliance checks
These services enable manufacturers to qualify suppliers, benchmark product performance, and reduce risk before issues occur in the field or during production.
Wide Scope of Accreditation at your Services
Learn More About QAI Materials Services
SPECIFIC TESTS AND/OR PROPERTIES MEASURED
METALS, METALLIC COMPONENTS, SYSTEMS AND ASSEMBLIES
FREQUENT TESTING METHODS/STANDARDS
• ASTM E2332 – Failure Analysis Standard Practice
• ASTM E3 – Metallographic Preparation
• ASTM E407 – Microetching Metals
• ASTM E18 – Hardness Testing
• ASTM E8 – Tensile Testing of Metals
• ASTM E23 – Charpy Impact Testing
• ASTM D638 – Tensile Testing of Plastics
TYPICAL PROJECTS WE SUPPORT
• Weld and fastener failure investigations
• Heat-treated metal part failures
• Polymer and plastic component fractures
• Fractography and fatigue testing
• Medical device and aerospace part analysis
• Contamination-related failures in food or industrial systems
• Reverse engineering and vendor qualification failures
Utilizing QAI’s expertise, efficient turnaround times, and dedicated customer service, ensures your medical devices meet regulatory standards promptly and effectively. This facilitates a quicker market entry while maintaining adherence to the highest safety and compliance requirements.
Note: For services specific to our Loves Park lab (formerly Atrona Test Labs), please call us directly at 📞 (815) 229-8620.
For all other inquiries or to reach our other labs and locations, please contact us at:
📞 USA 888.540.4024 📞 CANADA 877.461.8378
Founded in 1995 by a group of experienced certification and testing experts, QAI is an independent third-party testing, inspection and certification organization which serves the building industry, government and individuals with cost effective solutions through our global, in-house capabilities / services.
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USA 1(888)540.4024
Canada 1(877)461.8378
Europe info@qai.org
China china-info@qai.org
S Korea asia-info@qai.org