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Failure Analysis And Prevention

By Prof. D K Dwivedi   |   IIT Roorkee
Learners enrolled: 465   |  Exam registration: 6
About the course:
The course content is designed to systematic understanding on various aspects related with failure such as fundamental sources of failure of mechanical components, industrial engineering tools relevant to failure and failure analysis, general procedure of failure analysis through sample collection, preparation and preservation, testing, macro and microscopic observation of fracture, mode of fracture, metallographic procedure and image analysis, use of fracture mechanics and fracture toughness principles in failure analysis and analysis findings and report/recommendation writing. Presentation will include case studies to communicate concepts and procedures effectively. Case studies will be taken up from failure analysis of weld joints in different sectors. 


INTENDED AUDIENCE  :UG and PG Student, Research Scholar & Practicing Engineers

INDUSTRY SUPPORT  :Heavy engineering and pressure vessel industry, power plants
Summary
Course Status : Upcoming
Course Type : Elective
Language for course content : English
Duration : 12 weeks
Category :
  • Mechanical Engineering
Credit Points : 3
Level : Undergraduate/Postgraduate
Start Date : 20 Jan 2025
End Date : 11 Apr 2025
Enrollment Ends : 27 Jan 2025
Exam Registration Ends : 14 Feb 2025
Exam Date : 04 May 2025 IST

Note: This exam date is subject to change based on seat availability. You can check final exam date on your hall ticket.


Page Visits



Course layout

Week 1:

Module 1: Introduction: Need and scope
Module 2: Fundamental sources of failure
Module 3: Failures due to deficient design
Module 4: Failures due to improper materials selection
Module 5: Failures due to improper imperfections in materials

Week 2:

Module 1: Failures due to improper manufacturing
Module 2: Failures due to improper service and maintenance
Module 3: Industrial engineering tool relevant failure analysis
Module 4: Pareto analysis 
Module 5: Fault tree diagram

Week 3:

Module 1: Reliability and failure analysis
Module 2: FMEA and Weibull analysis
Module 3: General procedure of failure analysis
Module 4: How to proceed for failure analysis
Module 5: Familiarizing with failure: background info

Week 4:

Module 1: Sample: selection, collection, handling, preservation
Module 2: Testing of samples: NDT and DT of samples
Module 3: Identification of mode of failure
Module 4: Macroscopic observation of fracture surface: I
Module 5: Macroscopic observation of fracture surface: II

Week 5:

Module 1: Microscopic observation of fracture surface: I
Module 2: Microscopic observation of fracture surface: II
Module 3: Chemical analysis for failure investigation
Module 4: Metallographic examination of samples
Module 5: Image analysis of microstructures

Week 6:

Module 1: Fracture mechanics in failure analysis
Module 2: List of question to ensure proper investigation
Module 3: Analysis, report preparation, and recommendation
Module 4: Failure analysis of welded joints
Module 5: Failure of weld joints from HAZ

Week 7:

Module 1: Fracture toughness and its parameters: k, CTOD, J in
Module 2: Significance of SIF, CTOD
Module 3: Testing of fracture toughness
Module 4: Fatigue failure of weld joints
Module 5: Estimation of fatigue life using fracture toughness concept

Week 8:

Module 1: Failure of weld joints from fusion zone
Module 2: Failure of weld joints due to low temperature exposure
Module 3: Failure of weld joints due to high temperature
Module 4: Failure of weld joints due to SCC
Module 5: Failure of weld joints due to intergranular cracking

Week 9:

Module 1: Failure Analysis of Casting: Common Causes
Module 2: Failure Analysis of Casting: Cast Iron Sluice Valve
Module 3: Failure Analysis of Casting: Basics of Al-Si Alloys
Module 4: Failure Analysis of Casting: Al Alloy Casting
Module 5: Failure Analysis of Casting: Steel Casting

Week 10:

Module 1: Failure Analysis of Forming: Forming Related Issues
Module 2: Failure Analysis of Forming: Rolling Related Issues
Module 3: Failure Analysis of Forming: Defects in Formed Components
Module 4: Failure Analysis of Forming: High Strength Steel
Module 5: Failure Analysis of Forming: High Strength Steel Weld Joints

Week 11:

Module 1: Failure Analysis of Gear: Material, Manufacturing & Surface Condition
Module 2: Failure Analysis of Gear: Material, Manufacturing & Surface Condition
Module 3: Failure Analysis of Steel: Improper Heat Treatment
Module 4: Failure Analysis of Steel: Improper Case Hardening Treatment
Module 5: Failure Analysis of PH Aluminium Alloy: Improper Heat Treatment

Week 12:

Module 1: Failure Analysis of Weld Joints: Common Causes of Weld Joint Failure
Module 2: Failure Analysis of Weld Joints: Carbon Steel
Module 3: Failure Analysis of Weld Joints: Cracking of Steel Weld Joints
Module 4: Failure Analysis of Weld Joints: Austenitic Stainless Steel Weld Joints
Module 5: Failure Analysis of Weld Joints: Dissimilar Steel Weld Joints

Books and references

Becker et al. Failure analysis and prevention, ASM Handbook (2002) Hutching et al. Failure analysis, ASM International (1981) Besterfield et al. Total quality management, Pearson (2002)Engineering failure analysis, Journal, Elsevier Failure analysisand prevention, Journal, Springer .

Instructor bio

Prof. D K Dwivedi

IIT Roorkee
Prof. D K Dwivedi obtained BE (mechanical engineering) , in 1993 from GEC Rewa, ME (welding engineering) Univ. of Roorkee in 1997 and PhD in Met. Engineering from MNIT, Jaipur in 2003. He has about 9 years teaching experience at NIT Hamirpur and 19 years at IIT Roorkee of subjects related with manufacturing at UG level and welding engineering related subjects at PG level. He has published more than 132 research papers in SCI/SCIE indexed journals and undertaken 24 sponsored research and 54 industrial consultancy projects. Instructor has authored five books entitled “Production and Properties of Cast Al-Si Alloys with New Age International, New Delhi (2013), Surface Engineering, Springer Nature (2018), Fundamentals of Metal Joining, Springer Nature (2021), Materials Engineering, AICTE (2022), Dissimilar metal joining, Springer Nature (2023)

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
Date and Time of Exams: May 4, 2025 Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 8 assignments out of the total 12 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100

Final score = Average assignment score + Exam score

Please note that assignments encompass all types (including quizzes, programming tasks, and essay submissions) available in the specific week.

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.

Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Roorkee .It will be e-verifiable at nptel.ac.in/noc.

Only the e-certificate will be made available. Hard copies will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team


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