As failure analysis experts we apply metallurgy and engineering principles to find the root cause of product failures, equipment failures, and quality problems. We work with manufacturing companies, insurers, and attorneys.
Industrial Metallurgists is a trusted resource for failure analysis of metal parts and assemblies that fail during testing, manufacturing, or use. Using advanced analytical techniques and with years of hands-on experience, we uncover the root causes of failures and deliver insights that enable informed engineering decisions. Industry experience includes automotive, aerospace, hardware, tools, medical and dental devices, plumbing, industrial equipment, machinery, structures, electronics, and many more.
Our failure analysis services go beyond surface-level findings. We will provide you with a clear picture of why the failure occurred and steps to take to prevent recurrence. When you hire us, you hire a metallurgist, failure analysis expert, and an engineer.
On this page we share our unique process for helping clients solve problems.
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Industrial Metallurgists is the authoritative voice in failure analysis and trusted partner to industry leaders. The head of our consulting is Michael Pfeifer, Ph.D., P.E., a failure analysis expert with world-wide experience, and one of the most experienced metallurgical consultants in the industry.
With a career spanning over a quarter of a century, Michael is a pioneering force in the field of metallurgy and a failure analysis expert. His metallurgy expertise coupled with extensive product design and manufacturing experience gives him a unique and pragmatic perspective when working with clients. His specialized nine-step failure analysis process is product of his experience and perspective, and has become a cornerstone in metallurgical consulting.
We also develop and and sell online metallurgy courses that are geared to non-metallurgist engineers, including design, quality, manufacturing and reliability engineers. These courses have been taken by engineering professionals across the United States and around the world. Our courses are also sold by a few of the largest engineering organizations including Society for Automotive Engineers (SAE), American Welding Society (AWS), and Metal Service Center Institute (MSCI).
Michael is also the author of "Materials Enabled Designs," a book that's gained widespread respect and admiration among industry leaders in product design and manufacturing. His unique perspective and deep understanding of the intricacies of metals and product design and manufacturing make him the perfect ally for addressing complex challenges.
See the About page for more about our background and experience.
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We'll be part of your team during the failure analysis process. We don't just do an analysis, give clients a lab report, and leave it to them to figure out how to use the information. Part of being a failure analysis expert is understanding how to help clients engineer solutions to failures and problems. See this case study.
Time and action make a difference. Let’s talk today.
NEED HELP? SCHEDULE A FREE MEETINGAl McGovern, Director Mechanical Engineering
Shure Inc., Illinois
Stuart Gordon, President
Bestway Products Co., California
Our primary mission is to help clients solve complex manufacturing and product failure issues quickly and cost-effectively. We do this using our unique Nine-Step Failure Analysis Process, meticulously designed by our lead consultant, Michael Pfeifer, Ph.D., P.E., a failure analysis expert. This process leverages decades of metallurgical expertise to get to the root of the problem swiftly and provide effective solutions.
Over the past 25 years, our failure analysis services have been honed to perfection, underpinned by hands-on experience with a diverse client base. The key to effective failure analysis lies in the convergence of our robust design and manufacturing experience and solid engineering know-how.
As your collaborative partner, we seamlessly integrate into your engineering teams, working with them to plan analyses and use the findings to identify root cause and solutions.
Our failure analysis services merge our extensive experience with our meticulously crafted 9-step process to deliver tangible results. Working with us means unlocking the potential for heightened productivity, improved quality, and ultimately, amplified profits.
Metallurgical failure analysis is the first step of the root cause analysis process. For failures during testing and use, a failure analysis is performed to determine the failure mode and failure mechanism of the failed item, whether any metallurgical characteristics of the failed item contributed to the failure, and the metallurgical reason for the failure. For quality problems, a failure analysis is performed to assess metallurgical characteristics of the problem item, whether they meet the item’s specifications, and the metallurgical reason for the problem. The information obtained from a failure analysis is then used to identify the root cause of the failure or quality problem.
See our YouTube Channel for videos on failure analysis and different topics of metallurgy and metallurgical engineering for product design and manufacturing.
In the challenging landscape of manufacturing, the phrase "time is money" holds more truth than ever. Each minute lost to a failing component, an inefficient process, or a flawed product can translate into significant financial losses. The key to making consistent progress in such a demanding environment is having a deep understanding of the issues at hand. And this is where expert failure analysis comes into play.
Failures within manufacturing and production processes can be complex, often requiring a multidisciplinary approach to decipher their origins. They could stem from factors as varied as material defects, improper design, manufacturing anomalies, or environmental impacts. Without the right expertise, isolating the root cause from such a multitude of possibilities can be like finding a needle in a haystack.
A failure analysis expert, like Michael Pfeifer, Ph.D., P.E., comes armed with years of experience, deep engineering knowledge, and a systematic approach to uncovering the root causes of failures. Dr. Pfeifer's Nine-Step Failure Analysis Process is designed to methodically dissect the problem, leaving no stone unturned. This kind of comprehensive approach is key to making substantial progress, as it allows for targeted, effective solutions rather than mere stop-gap measures.
Moreover, proper failure analysis conducted by a failure analysis expert offers more than just immediate solutions. It can be an invaluable learning opportunity, transforming failures into stepping stones for future success. Understanding why a failure occurred can provide insights into improving design, refining manufacturing processes, and implementing robust quality control measures.
Consequently, the knowledge and insights gained from expert failure analysis can drive significant improvements in efficiency, reliability, and profitability, ultimately leading to steady progress and growth.
In conclusion, without expert failure analysis, an organization risks being stuck in a cycle of repeat failures, resulting in wasted time, resources, and stunted progress. Invest in expertise like Dr. Pfeifer's to unlock the potential of failure analysis and turn challenges into opportunities for advancement.
The best step to take when a metal problem occurs is to call a metallurgist. In every case I have ever worked for a client, the benefits of involving a metallurgist quickly outweighed the cost, time, or effort used with any other approach. Just like any problem in life, when done properly, formal failure analysis saves money, effort, and time. What distinguishes us from other metallurgical organizations is metals engineering expertise combined with lots of experience with every aspect of product design and manufacturing. With this broad experience, we bring multiple perspectives to help clients quickly get the information they need to solve problems and help them use the information to solve the problem.
Understanding what causes your metal failures is key to preventing them from happening again. We will get you the information you need to help you identify the root cause and the corrective action to prevent the problem from reoccurring. Hire us to find out what’s wrong with your product, equipment, or manufacturing process so that it doesn’t fail again!
Check out this classic book about component failures: Understanding How Components Fail, 3rd Edition
Imagine having a team of professionals dedicated to providing solutions for metal failures, regardless of where or when they occur. They can help you pinpoint the root cause and provide you with recommendations on how best to prevent the failures from occurring again. For people involved with product design and manufacturing, learning more about failure analysis will help you productively deal with component failures and quality problems. Want to learn more? Take our failure analysis course or webinar.
Needs Review Every failure analysis project starts with a conversation with your engineering team to review the problem and collect background information. This is done by phone or internet meeting and usually takes 15 – 30 minutes. There’s no charge for this step. We’ll review photos and drawings of the problem component or material and discuss the circumstances of the problem. We will also discuss the project scope, the metallurgical analysis and samples required, and approximate cost.
Identify the Project Approach This is where I use my experience, training, and knowledge to identify the best path forward. This includes metallurgical analysis of components or metal stock. Selecting the appropriate metallurgical analyses and samples to examine is critical to get information that enables finding the cause of the problem and preventing it from reoccurring. The approach might also include review of technical literature and discussions with suppliers.
Project Quote A project quote includes the project scope, the work to be performed, and the cost. After you approve the work we begin right away, and we meet or beat our timelines. We understand that failure analysis work is time sensitive.
Perform the Analyses The metallurgical analyses are performed, and the data is collected and reviewed. The analysis information combined with the background information is used to identify the metallurgical cause of the problem and possible root causes.
Review data We review the analysis findings with you and discuss possible root causes. At this point your input is important. The metallurgical analyses results will indicate the conditions that cause the failure and whether there was anything metallurgically wrong with the metal. However, more background information is often needed to use the analysis to identify the root cause. Your knowledge about the item’s design, manufacturing, and use is important.
So, we won’t just give you a report and leave it to you to figure out how to use the information to fix your problem. We work with clients to help them use failure analysis results to understand how the failure or problem occurred, its root cause, and how to prevent it from reoccurring. This distinguishes us from other failure analysis companies. We do more than just forensics - we help engineer solutions.
Written Report and Support Once you have your reports and understand the findings we continue to support you throughout the implementation of the changes recommended. One reason to choose Industrial Metallurgists is because of our ongoing support during implementation.
Check out Michael Pfeifer's articles about metals and product reliability on the Accendo Reliability website
