Need help with a metal failure analysis?

We help clients with metallurgical failure analysis of metal components to help determine the root cause of:

  • Component and product failures during testing or use
  • Supplier quality problems
  • Manufacturing quality problems

Industry experience includes automotive, aerospace, hardware, tools, medical and dental devices, plumbing, industrial equipment, machinery, electronics, and many more.

Materials experience includes ferrous metals, non-ferrous metals, coatings, and electronic materials.

Clients include manufacturers, insurance companies, and lawyers.

Further down the page is a list of past projects


More than just failure analysis

We won’t just give you a report and leave it to you to figure out how to use the information to fix the problem. We use the information obtained from the analysis to help clients understand how the failure or problem occurred, its root cause, and how to prevent it from reoccurring.


Typical process

    1. Review the problem with you and collect background information. No charge for this.
    2. Determine the metallurgical analyses required.
    3. Provide a quote for the project.
    4. Perform the analyses.
    5. Review the findings with you on the phone or via an online meeting, discuss possible root causes of the failure or problem, and help you identify corrective actions.
    6. Provide a written report, if desired.

Experience and background

For over 25 years we’ve been providing metals engineering expertise for failure analysis and forensic investigations of metal components and products. We’ve worked on hundreds of projects, and “tell it like it is”, so you can count on getting the support and advice needed to make well-informed decisions.

What distinguishes us from other companies is metals engineering expertise combined with lots of experience working on every aspect of product development 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.

To learn more about my expertise and experience, read here


Call to discuss your problem or project – 847.528.3467. Or send a message

    Past projects

    • 304 stainless steel mixing blades – fatigue fracture
      Fractured forged 1045 steel
      Fractured forged 1045 steel
    • Nitronic stainless steel wire component – inconsistent springback during forming
    • Copper tube – identify surface residue and origin
    • Crimped high-power component – determine whether crack was in braze joint
    • Washing machine brass hose connector – Identify root cause of corrosion and fracture
    • Hastelloy C-22 equipment – cracking near weld joints
    • Grade 5 hex head steel screw – fracture
    • Welds between cast 1045 steel parts – weak weld joints
      Coated steel corrosion
      Coated steel corrosion
    • Coated steel container – corrosion during product testing
    • 430 stainless steel sheet metal cracking during component fabrication
    • Motor electrical steel too strong and hard
    • Battery connector – corrosion
    • Integrated circuit solder joint – fractured
    • 440C stainless steel heat treatment – component too soft
    • PH stainless steel component – cracking during manufacturing
    • A2 tool steel fixturing component – wear during use
    • 6061 aluminum shaft – fractured
    • Steel shaft – fractured
      Sensitized 316 stainless steel
      Sensitized 316 stainless steel
    • 4140 steel swedge – fractured
    • Brass plumbing component – fractured
    • 3003 aluminum power supply housing – electrical damage
    • Stainless steel sheet – corrosion from muriatic acid fumes
    • Brass faucet – leak
    • Clogged pumps – Identify origin of particles causing clogs
    • Flexible printed circuit board (PCB) interconnection – cracked metal
    • 3003 aluminum sheet – Identify source of surface contamination
    • 316 stainless steel gas hose – identify cause of sensitization
    • Forged 1045 steel component – fractured

    Michael Pfeifer, Ph.D., P.E.
    Principal Engineer and Trainer or 847.528.3467