Fractography Analysis

We investigate a wide range of metallic materials (aluminum, steel, titanium, nickel alloys, copper), from welds and castings to finished parts. Our approach addresses situations where mechanical integrity directly impacts performance and safety—such as aerospace parts, industrial machinery, or critical pipeline welds. Whether suspect corrosion or advanced embrittlement, we bring global resources to help you act swiftly. 

Key materials we analyze: 

• Structural metals & alloys 

• Welded assemblies and joints 

• Cast components (iron, steel, nickel, etc.) 

• Engineering components for critical applications 

• Industrial parts requiring root cause analysis 

We categorize fracture characteristics, identifying features like fatigue striations, cleavage/brittle fracture patterns, microvoid coalescence in ductile failures, and intergranular decohesive rupture. Our testing reveals precise crack propagation trends and service loading conditions.

Analysis capabilities include:

• Fatigue fractography (Stage I, II, III progression)
• Cleavage & brittle fracture evaluation (river patterns, chevron marks)
• Dimple rupture analysis (microvoid coalescence in ductile overload)
• Decohesive rupture detection (intergranular failure, e.g., hydrogen embrittlement)
• Service loading condition correlation

Failures we test for and what they mean:

Fatigue Fractography

Fatigue arises from repetitive loading. We examine fatigue striations, determining crack initiation (Stage I), propagation (Stage II), and total separation (Stage III). This tells us where material failure began and ended.

Cleavage Failure Mode

Cleavage is a low-energy fracture under severe constraint or brittle states. We verify features like river patterns and feather markings that confirm transgranular cleavage—critical for preventing sudden overload failures.

Dimple Rupture Mode

When materials overload in a ductile condition, dimple rupture occurs. Our experts spot microvoid coalescence features to confirm ductile failure. This helps optimize material choice and design geometry.

Decohesive Rupture Mode

Decohesive rupture is an intergranular failure with minimal plastic deformation, often involving hydrogen embrittlement, stress corrosion cracking, or heat treatment embrittlement. Paired with full failure analysis, fractography pinpoints embrittlement causes and prevention strategies.

Using scanning electron microscopy (SEM) and advanced analytical tools, we deliver in-depth failure investigation, from crack initiation to final part separation. This approach is especially beneficial when corrosion or contamination suspicion arises. We document fracture surface topography, identify micro- and macro-scale features, and trace the root causes—be it mechanical overload or chemical embrittlement.

 Our analytical approach includes:

• Crack initiation & propagation mapping
• Surface feature characterization (river patterns, chevron, feather markings)
• Microstructural & metallurgical analysis
• Root cause determination (e.g., hydrogen embrittlement, corrosion, mechanical overload)
• Actionable prevention recommendations

Our labs house state-of-the-art SEM with energy dispersive X-ray spectroscopy (EDS), enabling us to visualize fracture surfaces at high magnifications and analyze local chemical composition. This synergy of metallurgical testing and fractography gives you a frictionless path to conclusive failure analysis results.

Our team operates from Materials Testing Services hubs across the world, providing global access to our expert capabilities. Find your nearest Materials Testing Services hub on our Locations Page. 

We merge fractography findings with metallurgical testing to develop targeted solutions and practical recommendations—spanning material selection, design modification, or operating condition adjustments. By connecting fracture analysis to everyday engineering decisions, we help ensure that similar failures never recur. 

Key prevention strategies: 

• Material selection optimization (resistance to embrittlement, corrosion, etc.) 

• Design improvements (reducing stress concentrators) 

• Operating condition guidelines (avoiding critical temperatures, loading states) 

• Maintenance protocol development (preventing early crack initiation) 

• Quality control enhancements to spot manufacturing defects