Failure analysis
Failure analysis is a specialized service at INFINITIA applied to accurately identify the origin of failures in materials, components, and industrial systems, enabling a clear understanding of the real causes behind incidents in production, in the product, or following a market claim.
In our failure analysis laboratory for materials and components, advanced characterization techniques, experimental testing, and forensic engineering methodologies are combined to evaluate everything from material microstructure to real operating conditions. We investigate the causes of failures and propose more effective solutions. This approach allows us to address complex problems involving variables related to design, manufacturing, assembly, transportation, maintenance, or final use.
The objective is to provide an evidence-based technical diagnosis that enables companies to correct errors, establish responsibilities when necessary, and define effective actions to prevent the issue from recurring. This service is particularly relevant in industrial sectors where product functionality, quality, safety, and durability cannot tolerate uncertainty.
What does failure analysis and root cause analysis consist of?
Failure analysis is a structured technical process aimed at investigating why a material, component, joint, or system ceases to function as intended, carrying out analysis to correct the causes. Its purpose is not only to describe visible damage, but to determine the failure mode and the cause of failure—that is, to understand how the incident occurred and why it led to that outcome, which is critical for process improvement. In industrial practice, this type of study is essential when fractures, deformations, unexpected corrosion, performance loss, aesthetic defects, or any anomaly that compromises functionality or product quality appear.
From a forensic engineering and failure engineering perspective, this work requires analyzing the complete context of the problem. It is not enough to observe the damaged part; it is necessary to reconstruct what happened by considering design, materials used, manufacturing process, service conditions, transportation, storage, and even final use. Therefore, failure analysis relies on a combination of document review, interviews with involved stakeholders, visual inspection, material characterization, and specific testing to obtain objective evidence.
At INFINITIA, failure analysis in materials and components is approached as both a diagnostic and decision-making tool. When the problem has already occurred, the goal is to identify the root cause and prevent recurrence. When still in the design or industrialization phase, methodologies such as Failure Mode and Effects Analysis (FMEA) can be used as complementary tools to anticipate risks, prioritize actions, and improve product or process robustness. In this way, failure analysis not only helps understand past incidents but also generates valuable knowledge to reduce their future likelihood through failure mode analysis.
Benefits of failure analysis for quality, causes, and effects
One of the main benefits of failure analysis is enabling companies to move from suspicion to evidence when an incident occurs in production or service. At INFINITIA, we work with components that fail without an apparent cause, where it is necessary to determine whether the origin lies in the material, design, manufacturing process, or unforeseen usage conditions. This approach avoids ineffective corrective actions and allows direct intervention on the real cause, reducing costs and preventing recurrence.
We also address issues that directly affect final product quality through the analysis of complex systems, aiming to understand the root of deficiencies. It is common to analyze parts presenting defects such as discoloration, premature wear, corrosion, or loss of functionality, where the origin is not evident at first glance and requires root cause analysis. In these cases, analysis helps identify material incompatibilities, process deviations, or equipment-related errors. These studies are essential for manufacturers who need to ensure product uniformity and avoid deviations in mass production.
Furthermore, the service is particularly relevant in market claims, where the origin of failure may be ambiguous. It may be related to human error or usage conditions. At INFINITIA, we analyze returned products or customer-reported incidents to determine whether the issue originates from manufacturing, transportation, design, or misuse. This approach supports technical reporting, establishes responsibilities, and defines proportionate corrective actions, addressing the causes that may have contributed to the incident. Overall, these benefits lead to improved quality control, reduced uncertainty, and increased product reliability in the market.
Failure analysis at INFINITIA. Ishikawa diagram and fault tree analysis.
At INFINITIA, we approach failure analysis using analytical methods and tools such as the Ishikawa diagram, following the Kaoru Ishikawa approach, recognizing that industrial incidents rarely have a single cause. It is common to encounter combinations of factors such as out-of-spec raw materials, weak tolerances, unforeseen interactions between components, deviations in manufacturing processes, or more demanding service conditions than expected. Therefore, we structure the analysis to evaluate all these variables in an integrated way, avoiding partial interpretations that could lead to ineffective solutions or recurrence.
We work with components and products showing physical evidence of failure, such as fractures, corrosion, wear, or degradation, where correct interpretation of material history is essential. To achieve this, we combine microstructural characterization techniques, chemical analysis, surface evaluation, and specific testing to identify alterations, residues, or damage patterns. This approach transforms an incident into useful technical information, distinguishing between plausible hypotheses and evidence-based conclusions through experimental validation, including fault tree analysis.
Additionally, the service has a direct impact on industrial decision-making by addressing the causes of inefficiencies. At INFINITIA, we help companies define concrete actions based on analysis, such as redesigning components, adjusting processes, reviewing specifications, selecting materials, or modifying usage conditions. This work is complemented, when necessary, with methodologies such as design or process FMEA to prioritize risks and optimize implemented solutions, using valuable information to improve decision-making. The result is improved quality control, reduced failure-related costs, and increased product reliability in real applications.
How we perform failure analysis at INFINITIA?
At INFINITIA, failure analysis is carried out through a structured methodology that combines contextual investigation, experimental analysis, technical validation, and root cause analysis to explore the causes of problems.
Our approach goes beyond identifying the failure, focusing on understanding its real origin and translating it into concrete industrial decisions, adapting each study to the type of material, component, and operating environment.
Technical failure diagnosis and analysis methods
The first step is to analyze the context in which the incident occurred, gathering information about design, manufacturing process, usage conditions, and involved stakeholders. This initial analysis defines the scope of the problem and establishes the first hypotheses regarding the origin of the failure, applying analytical methods.
At INFINITIA, we complement this phase with visual inspection, comparative analysis between OK and NOK samples, and document review, enabling identification of patterns and focusing the study on the most relevant technical variables.
Experimental analysis, characterization, and hypothesis validation
Based on the initial diagnosis, advanced material characterization techniques and specific tests are applied to evaluate component behavior. This includes microstructural, chemical, mechanical, or surface analysis depending on the type of failure, enabling identification of damage mechanisms, detection of component failures, and assessment of associated risks.
At INFINITIA, each experimental strategy is designed in a customized way, combining standardized techniques with tests adapted to real operating conditions. Once possible causes are defined, tests are carried out to reproduce or simulate failure conditions, allowing hypothesis validation and confirmation of the root cause through experimental evidence, avoiding conclusions based solely on observation.
Implementation of solutions and continuous improvement
Failure analysis does not end with identifying the cause, but with defining and implementing corrective and preventive actions. These may include changes in design, material selection, process parameters, or usage conditions, always aligned with the real origin of the problem.
At INFINITIA, we support companies in implementing technical solutions, improving product reliability, reducing operational risks, and preventing recurrence. This approach also contributes to process optimization and reinforces continuous improvement based on validated technical knowledge.
Failure analysis methodology: structured and evidence-based approach to determining failure modes
Failure analysis in materials and components is based on a structured process that evolves as information is obtained. Although each case requires a specific approach, the methodology follows a common logic aimed at reducing uncertainty and validating each conclusion through technical evidence.
Unlike linear or simplified approaches, failure analysis is an iterative process in which each phase refines the understanding of the problem. Root cause identification is rarely immediate but results from a progressive analytical process combining experimental data, technical interpretation, and validation through failure mode analysis.
This approach enables tackling complex failures involving multiple variables, avoiding diagnostic errors and ensuring decisions are based on verified information. It also facilitates integration of complementary risk analysis tools when prioritization of actions is required, breaking down the involved factors.
What is Failure Mode and Effects Analysis (FMEA)? Complementary tool to failure analysis.
Failure Mode and Effects Analysis (FMEA) is a methodology used as a complement to failure analysis to identify, evaluate, and prioritize risks in products and processes. Unlike forensic analysis, which focuses on failures that have already occurred, FMEA is a preventive approach aimed at anticipating potential incidents, using the central spine concept to identify risks.
Functional FMEA
It allows analysis of the overall functioning of a system, identifying potential failures in each function. The effects of these failures are evaluated within the system, enabling detection of critical points before they materialize.
At INFINITIA, we apply this approach to understand how a local failure can affect overall product performance, facilitating identification of systemic risks.
Design FMEA
It focuses on evaluating how product design can generate failures throughout its lifecycle. Aspects such as material selection, geometry, tolerances, and component interaction are analyzed to understand the root of deficiencies.
This analysis allows anticipation of design-related issues before manufacturing, improving product robustness and reducing failure probability in service.
Process FMEA
It analyzes production process stages to identify potential failures affecting product quality or performance, identifying cause-effect relationships at each stage. Factors such as machinery, environmental conditions, manufacturing methods, or human intervention are evaluated.
At INFINITIA, we use process FMEA to complement failure analysis, allowing not only understanding what happened but also preventing recurrence through process optimization.
Applications of failure analysis in materials, components, and industrial processes
At INFINITIA, failure analysis is applied in various industrial contexts, from production line incidents to complex market claims after product release. Although symptoms may vary, the technical approach remains consistent: understanding context, identifying damage mechanisms, discriminating between possible causes, and validating the determining variables.
Our goal is to transform each failure into a technically grounded decision, combining material analysis, process review, OK/NOK comparison, and reproduction of real operating conditions. This approach not only explains the origin of the issue but also enables correction and prevention, adding direct value to industrial decision-making.
Failure diagnosis in materials and components
These analyses identify what has failed in materials and components that have lost functionality or present fractures, cracks, deformations, or unexpected degradation, helping understand what failure analysis entails. The origin and mechanism of damage are studied, such as fatigue, corrosion, embrittlement, wear, creep, or chemical incompatibility, combining microstructural characterization, chemical analysis, and surface evaluation in metals, polymers, coatings, adhesives, or multimaterial systems.
At INFINITIA, this approach is used to determine whether the failure originates from the material, its processing, component interaction, or real usage conditions. This diagnosis supports decisions such as redesigning parts, adjusting tolerances, modifying specifications, or validating suppliers, providing a solid technical basis for improving reliability and supporting decisions in quality, production, or client contexts.
This type of analysis is particularly relevant in critical validation phases or recurring incidents, where accurate root cause identification prevents superficial solutions and reduces future failure probability.
Production line failures
These analyses detect critical incidents in production lines caused by process errors, handling issues, machinery malfunction, or environmental conditions, improving system efficiency. All production stages are systematically reviewed, from raw material reception to final product, identifying deviations that may lead to defective, contaminated, deformed, or out-of-spec parts.
At INFINITIA, we analyze complete manufacturing processes, identifying failures in process parameters, equipment maintenance, quality control, or interaction between operations. This enables precise corrective actions, reduction of scrap, minimization of rework, and avoidance of production stoppages, improving process stability and overall plant efficiency through data analysis.
Additionally, this approach helps detect systemic failures not evident in isolated controls, strengthening process robustness and improving detection capability before defects impact final products.
Finished product failures
These tests evaluate defects detected in finished products, both functional and aesthetic, such as discoloration, loss of adhesion, premature wear, accelerated ageing, deformation, or surface degradation. The analysis determines whether the product meets intended usage conditions and aligns with technical specifications and customer expectations.
At INFINITIA, we use this analysis to determine whether failures originate from design, material, manufacturing process, or a combination of factors, using fault tree analysis or inverted tree diagrams. These studies allow correction of deviations before new production runs, optimization of design, and improvement of product durability, reducing returns and enhancing perceived quality.
This evaluation is essential in high-value or aesthetically demanding products, where minor deviations can significantly impact customer acceptance and competitiveness.
Market claims and responsibility assessment
These analyses investigate incidents after product commercialization, determining whether the failure originates from manufacturing, transportation, storage, installation, or misuse. A detailed study of material evidence and usage context is conducted, reconstructing the conditions experienced by the product to correct possible causes of failure.
At INFINITIA, we analyze claimed products to identify usage traces, specific degradation, or original defects, supporting technical and expert reports when required. This approach allows clear assignment of responsibilities, accurate response to customers, and definition of appropriate corrective actions, reducing conflicts and improving traceability.
Additionally, these analyses provide valuable feedback for internal processes, improving product quality and reducing future market claims.
Hypothesis development and experimental validation
These tests validate potential causes of failure through controlled reproduction of real or simulated conditions. Different hypotheses, such as mechanical overload, chemical degradation, design errors, or environmental conditions, are evaluated through designed experiments to confirm or discard each scenario.
At INFINITIA, we develop specific tests to reproduce failures in laboratory conditions, adapting standardized methods or defining new protocols when necessary. This experimental validation confirms the root cause with objective evidence, reduces uncertainty, and ensures that implemented solutions are aligned with the real origin of the problem.
This approach is particularly useful in complex or multifactorial failures requiring rigorous verification to avoid incorrect conclusions.
Risk analysis and solution implementation
These studies assess severity, occurrence probability, and detection capability of failures, prioritizing actions through methodologies such as FMEA. The system is analyzed globally to identify critical points and define strategies to reduce recurrence risk.
At INFINITIA, this approach transforms diagnosis into concrete solutions, such as redesigning components, changing materials, adjusting processes, improving quality controls, or modifying usage conditions. It shifts from reactive to preventive strategies, optimizing decision-making and ensuring greater product reliability through risk management and prioritization.
As a result, companies can anticipate future failures, optimize processes, and strengthen product robustness from both technical and strategic perspectives using advanced analytics.
Industrial sectors where failure analysis is key to ensuring quality, safety, and reliability
Failure analysis has essential applications across a wide range of industrial sectors, as any system based on materials, components, and processes is exposed to technical incidents. However, failure mechanisms, regulatory requirements, and impact vary significantly between sectors, making it essential to adapt the analysis approach to each specific context.
At INFINITIA, we develop advanced failure analysis studies combining characterization techniques, experimental testing, and forensic engineering methodologies. Our goal is to interpret each incident within its real context, validate hypotheses, and provide valuable information for decision-making, ensuring product reliability and process robustness in every sector.
Automotive: failure analysis in components subjected to fatigue, wear, and variable conditions
In automotive applications, components are subjected to cyclic loads, vibrations, thermal variations, and aggressive environments, requiring effective analysis to prevent failures. High production volumes and strict quality requirements mean that small deviations can have significant impacts on warranties, safety, or brand reputation.
- Fatigue and wear failure evaluation: analysis of fractures, cracks, or degradation in cyclically loaded components, applying preventive measures.
- Material interface analysis: detection of issues in joints, coatings, or multimaterial assemblies.
- Service condition validation: study of temperature, corrosion, and accelerated ageing effects.
At INFINITIA, we work with suppliers to identify root causes in recurring failures, optimizing design, material selection, and manufacturing processes.
Energy industry: failure analysis in maintenance and materials under extreme conditions
In the energy sector, materials operate under extreme temperature, pressure, corrosion, abrasion, and continuous load conditions, where degradation may evolve into critical failures. Reliability and integrity are key to ensuring safety and avoiding unplanned shutdowns.
- Severe degradation analysis: study of localized corrosion, thermal fatigue, erosion, or embrittlement phenomena and their severity and effects.
- Integrity assessment: identification of failure mechanisms in pipes, heat exchangers, tanks, or structural components.
- Simulation of real conditions: reproduction of service environments through specific tests, enabling graphical representation of results.
At INFINITIA, these analyses help understand why solutions fail in service and allow redefining materials, optimizing maintenance strategies, and improving design criteria.
Chemical sector: failure analysis due to chemical incompatibility, degradation, and attack by aggressive substances
In the chemical and petrochemical industries, materials and components are exposed to highly aggressive environments that can lead to progressive degradation mechanisms which are often difficult to detect in their early stages. Prolonged interaction with chemical substances may alter the mechanical, chemical, or structural properties of a material, compromising system integrity and reducing its service life long before visible failure occurs.
- Chemical compatibility evaluation: analysis of the interaction between materials and chemical agents, identifying undesirable reactions, swelling, embrittlement, dissolution, or loss of performance caused by incompatible media.
- Degradation and ageing study: detection of structural changes, cracking, property loss, surface attack, or dimensional instability caused by long-term exposure to aggressive substances.
- Operational condition analysis: evaluation of the influence of temperature, concentration, pressure, cleaning cycles, contaminants, and process fluctuations on the development of the failure.
At INFINITIA, we analyze these scenarios to determine whether the failure originates from incorrect material selection, process-related degradation, formulation changes, or unexpected service conditions. This type of failure analysis is particularly valuable for redefining material selection criteria, revising operating protocols, and improving the safety and durability of equipment, installations, and components working in chemically demanding environments.
Electronics and appliances: failure identification in materials, assemblies, and in-service performance
In electronics and household appliances, failures often arise from the interaction between materials, assembly processes, and service conditions. Component miniaturization and demanding functional and aesthetic requirements mean that even minor deviations can lead to performance issues, quality complaints, or premature failure.
- Material failure analysis: study of thermal degradation, cracking, deformation, ageing, or loss of mechanical properties in metallic and polymeric components.
- Assembly evaluation: detection of failures in solder joints, adhesives, encapsulations, connectors, or interfaces between dissimilar materials.
- Usage validation: assessment of the influence of temperature, humidity, cleaning agents, repeated operation, and environmental exposure.
At INFINITIA, we identify the root cause of failures, distinguishing between design, materials, manufacturing, assembly, or use, enabling improved product design, optimized processes, reduced returns, and enhanced long-term reliability.
Construction and infrastructure: failure analysis in materials subjected to loads and prolonged environmental exposure
In construction and infrastructure, materials are exposed to long-term environmental conditions, structural loads, and service cycles that can lead to progressive deterioration. These failures may not be immediately visible but can evolve into critical issues affecting safety, durability, and maintenance costs.
- Environmental degradation analysis: study of corrosion, moisture, UV radiation, pollution, and thermal cycling.
- Structural defect evaluation: identification of cracking, deformation, adhesion loss, coating failures, or delamination.
- Durability assessment: analysis of long-term behavior and service life under real conditions.
At INFINITIA, we determine the origin of deterioration and define technically justified maintenance, repair, or replacement strategies, optimizing service life, reducing costs, and ensuring structural reliability.
Consumer goods: failure analysis in finished products and resolution of market claims
In consumer goods, failures directly impact customer perception and brand reputation, even when structural integrity is not compromised. Issues such as discoloration, early fracture, abnormal wear, or loss of functionality often lead to complaints and returns.
- Functional and aesthetic defect evaluation: analysis of discoloration, wear, deformation, adhesion loss, ageing, or breakage.
- Usage condition analysis: identification of failures caused by misuse, poor maintenance, or unexpected conditions.
- Claim investigation and reconstruction: reconstruction of the case to determine the real origin of the failure.
At INFINITIA, we differentiate between manufacturing defects, design issues, material problems, and misuse, helping companies respond rigorously to claims, improve internal processes, and reduce future incidents while strengthening product reliability and customer confidence.
The value of failure analysis at INFINITIA for risk management and industrial decision-making
Failure analysis is a key tool for transforming an incident into a well-founded technical decision. At INFINITIA, we approach every case through an evidence-based methodology that allows us to distinguish between root causes, contributing factors, and secondary effects. This prevents incorrect interpretations and ineffective corrective actions, ensuring that the measures adopted are aligned with the true origin of the problem.
By combining advanced characterization techniques, experimental testing, comparative analysis, and hypothesis validation, we help companies reduce risks before an issue escalates into production failures, customer returns, safety incidents, or repeated market claims. This generates validated learning that improves both product robustness and process reliability, while also making it easier to assess whether changes in design, materials, suppliers, manufacturing parameters, or service conditions are technically justified.
Failure analysis also has a direct economic impact. At INFINITIA, we support companies in reducing costs associated with scrap, rework, downtime, warranties, recalls, disputes, or unnecessary replacements by identifying the root cause at an early stage. Each well-resolved study generates actionable knowledge that can be applied to future developments, continuous improvement strategies, and more efficient industrial decision-making.
The future of failure analysis is increasingly linked to the integration of advanced risk methodologies, simulation tools, predictive validation, and structured approaches such as FMEA. At INFINITIA, we already work in this direction by combining forensic engineering, root cause analysis, experimental validation, and risk prioritization methodologies to strengthen the reliability of industrial systems and anticipate potential problems before they occur.
Working with INFINITIA means partnering with a specialized team in failure analysis of materials and components, with the capability to design tailored testing strategies adapted to each industrial context. Our goal is to provide rigor, confidence, and technical clarity in decision-making, ensuring not only that companies understand what happened, but also that they can act effectively to prevent it from happening again.
