The History of failure analysis describes how engineering and science have continually evolved to understand why and how a material, product, or structure fails. The primary objective of failure analysis is root cause analysis, which is to identify the root cause of a failure and prevent it from recurring in the future.
Today, this field is a vital part of industries such as aerospace, automotive, oil and gas, manufacturing, electronics, and construction. Let’s explore the history of failure analysis and its development stages in detail.
Before exploring the History of Failure Analysis, it is important to understand What is Failure Analysis
Early Origins of Failure Analysis
The history of failure analysis dates back to ancient times. When metal tools, weapons, and bridges broke, craftsmen tried to understand the cause. At that time, methods were not scientific, but rather based on trial and error.
Industrial Revolution (18th – 19th Century)
The Industrial Revolution in the 18th and 19th centuries gave a new form to failure analysis.
- For the first time, the causes of highway accidents and broken axles were systematically studied.
- Advances in metallurgy helped engineers understand the relationship between defects and material failure.
From this time onwards, the documented form of History of Failure Analysis started emerging.
Early 20th Century – Scientific Foundation
History of Failure Analysis got a scientific base in the 20th century.
- The Titanic disaster in 1912 focused attention on brittle fracture.
- Aircraft and weapons failures in World Wars I and II gave rise to fracture mechanics and fatigue analysis.
- Root cause analysis began to be used as a structured method.
Mid to Late 20th Century – Advanced Tools
The History of Failure Analysis is believed to have flourished between the 1950s and the 1980s.
- Non-Destructive Testing (NDT) methods such as X-ray and ultrasonic testing began to be used.
- Scanning Electron Microscopy (SEM) and X-ray diffraction made micro-level studies easier.
- Failure Mode and Effects Analysis (FMEA) and Reliability Engineering were developed in the 1960s.
Modern Era of Failure Analysis
In the 21st century, History of Failure Analysis has reached high-tech level.
Today, forensic engineering, Finite Element Analysis (FEA), and predictive maintenance tools are taking failure analysis to new heights. Its importance has increased in the aerospace, electronics, oil & gas, and construction industries.
Importance of Understanding the History of Failure Analysis
- It tells us how engineering has improved safety and reliability.
- It plays an important role in legal investigations and forensic engineering.
- It is used with modern tools to prevent accidents and improve designs.
Famous Case Studies in the History of Failure Analysis
1. Titanic Disaster (1912)
The sinking of the Titanic was caused not only by icebergs, but also by brittle fracture. The steel used in the ship became brittle at low temperatures, and the plates broke. This incident is very important in the history of failure analysis.
2. Liberty Ships – World War II (1940s)
The United States built Liberty Ships during WWII. Welded joints and poor-quality steel caused many ships to break up mid-ocean. This spurred research into fracture mechanics and welding practices.
3. De Havilland Comet Aircraft (1954)
The world’s first passenger jetliner crashed because its square windows developed fatigue cracks from stress concentration at the corners. After this, window designs in the aviation industry were always rounded.
Conclusion
The history of failure analysis shows that engineering is not limited to design and manufacturing, but rather the process of increasing safety and reliability by understanding failures. Railway accidents, shipwrecks, and aircraft crashes strengthened this field.
Today, with the advent of big data and predictive tools, failure analysis has become even more advanced. Its importance will only increase in the future.