Mechanical Failure Analysis

Capabilities and Services

• Mechanical Modeling & Simulation

  When designing a new product or analyzing failures of a product in the field, Exponent's mechanical engineers use state-of-the-art software to create mechanical models to predict and optimize product performance or better understand root-causes of field failures.

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• Mechanical Testing Services

  Whether evaluating a mechanical system failure or troubleshooting a new product, Exponent provides high-quality mechanical testing services in state-of-the-art facilities across the U.S. and internationally.

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• Summary of Services

  For 50+ years, we've thrived on solving unstructured problems that require bespoke solutions. Some of our services include:

  Assessments & Evaluations

  • State-of-the-art linear and nonlinear fracture mechanics and damage mechanics
  • Linear and nonlinear finite element analyses of structures ranging in scale from microelectronic chips to giant earthmovers — often involving complex contact, thermal stresses, and fluid-structure interaction
  • Application of ABAQUS, ANSYS, and COMSOL among other powerful software tools
  • Robust computer cluster facilitates modeling of complex industrial, medical, and consumer product mechanical failures
  • Failure analysis of mechanical systems, mechanisms, machinery, gears, bearings, shafts, pressure vessels, piping, valves, and fittings
  • Risk assessment of multiple product failures when a family of products shares a common flaw or is subject to misuse
  • Measurement of mode shapes, frequencies, and damping characteristics of vibrating equipment and structures

  Evaluation of Life Assessments

  • Conduct remaining life and fitness-for-service evaluation of structures, machinery, and process equipment undergoing fatigue

  On-Site Analysis & Global Mobilization of Services

  • Rapid response, worldwide, on-site failure analysis of critical manufacturing production facilities
  • Planning and execution of large-scale field investigations of mechanical failures, including photography, 3D scanning, surveying, and evidence collection, documentation, and preservation
  • Surveys of mechanically damaged equipment to determine the extent of the failure, repairability, and salvage value

  Laboratory Testing

  • Analyze fracture surfaces macroscopically and microscopically, calculate J-integral crack driving forces, and measure crack growth resistance
  • Apply cyclic loads to induce fatigue fracture using servo-hydraulic, electronic, mechanical, and vibratory testing machines to replicate failures
  • Apply impact loads to consumer products to simulate dropping and other end use scenarios

  Failure Analysis, Planning & Reconstruction

  • Planning and execution of mechanical testing programs to validate the failure resistance of new designs
  • Reconstruction of failures and accidents involving industrial machinery and construction equipment