Failure Investigations
Mechanical failures rarely have a single cause. Independent, evidence-based failure investigations identify root cause and justify remedies that improve joint reliability.
Why Failure Investigations Matter
Mechanical assemblies—particularly those involving bolted joints—operate under complex combinations of load, vibration, and environmental exposure. When failures occur, surface-level symptoms often mask deeper issues related to design assumptions, assembly practices, or operating conditions. A structured failure investigation helps to:
- Identify Root Cause
Move beyond symptoms to determine the underlying failure mechanism rather than isolated contributing factors. - Prevent Repeat Failures
Apply corrective actions that address the true cause, reducing the risk of recurrence across similar designs or products. - Support Engineering Decisions
Provide technically defensible conclusions that inform design changes, validation plans, and production controls.
By grounding conclusions in physical evidence and engineering analysis, failure investigations provide clarity in situations where assumptions or incomplete data can lead to costly missteps.
Investigation Approach and Capabilities
Failure investigations are tailored to the specific application, but commonly include a combination of the following:
- Failure history review and operating condition assessment
- Visual inspection and dimensional evaluation of failed components
- Load path and interface analysis
- Evaluation of joint behavior, including preload loss and separation risk
- Review of assembly methods, torque procedures, and process variability
- Comparison to applicable design assumptions, calculations, and standards
This structured approach ensures conclusions are supported by data, analysis, and sound engineering judgment.
Focus on Joint Reliability
Many mechanical failures trace back to joint behavior over time. In bolted assemblies, failures often stem from preload loss, fatigue, embedment, or sensitivity to installation variability. Understanding how loads are transferred through joints—and how those joints respond under real-world conditions—is central to identifying root cause.
Failure investigations frequently connect directly to improvements in bolted joint design, analysis, and validation, helping teams strengthen future designs and reduce long-term risk.
Actionable Findings and Recommendations
A failure investigation should deliver more than an explanation. Typical outputs include:
- Clear documentation of findings and failure mechanisms
- Identification of risks affecting related designs or products
- Engineering recommendations for design updates or validation testing
- Guidance on improving assembly controls and long-term reliability
These recommendations are intended to be practical, technically justified, and aligned with manufacturing and field realities.
Collaborate with Matrix Engineering
Failure investigations often work hand-in-hand with broader bolted joint consulting efforts. When joint behavior plays a role in a failure, investigation findings can directly inform design improvements, testing strategies, and validation plans.