Failure Analysis and Inspection Services 

Failure Analysis Investigations	On-Site Inspections
Materials Testing	Corrosion Testing & Investigations
Technical Audits for Construction & Manufacturing Facilities	On-Site Metallographic Investigations
Welding, Soldering & Brazing Failure Analysis	Metallurgical Investigations
Concrete (Petrographic) Analysis	Underground & Aboveground Pipe and Tank Investigations
Surface Analysis: AES, FTIR & X-ray	Plastics, Polymers, Paint & Coatings
Fracture Mechanics	Fractography (OLM, SEM & TEM)
Accident Investigations	Forensic Engineering
Micro & Macro-photography	Non-Destructive Testing (NDT)
Chemical and Mechanical Testing	FEA & Engineering Mechanics Analysis
Cathodic Protection	Material Selection

Selected Corresponding Technical Publications by Matco Personnel

Failure Analysis and Investigation Methods for Boiler Tubes

Laboratory and Field Corrosion Investigation of Galvanized Utility Poles

Failure Analysis of Coatings

A Re-Examination of Failure Analysis

Painted Galvinized Steel Case Histories

         Matco Associates, Inc. is a leading independent consulting, engineering, and testing firm specializing in the fields of failure analysis, corrosion, metallurgical engineering, cathodic protection systems, materials selection, concrete failure analysis and coatings. Matco's team of experienced professionals is fully qualified to investigate the causes of material failures. We also provide technical analysis, investigative research and development, and assistance in making the right material choices, particularly where the environment may be a consideration. Matco provides a unique blend of rapid turn-around times and creative problem solving abilities.

At Matco, we specialize in failure analysis and corrosion investigations. We will determine if a failure is caused by inappropriate material selection, design, fabrication or operating conditions. Major corporations that rely on Matco expertise include US Airways, Allegheny Energy, Follansbee Steel, General Electric, Southern California Edison, Sony Electronics, ABB Power and many more.

Some of the components for failure analysis that we look at in a typical day include mechanical equipment; superheater & boiler tubes; wire cables; pipelines; pressure vessels; forgings; castings; welds/brazes; tools and dies; gears; FRP/PVC pipe; and rebar.

Determination of the root cause of failure of systems or components can be very complex, and may require multidisciplinary testing and analysis. The first requirement for success is having a full-equipped modern laboratory. Matco’s labs include light and electron microscopy (SEM,AES, TEM), mechanical and corrosion & electrochemical testing, environmental testing, chemical characterization, FTIR, X-ray diffraction, electronic testing,  and fracture mechanics/FEA analysis capabilities.

The other half of the battle is having the right staff. Matco ‘s staff includes experienced PhD-level Metallurgists, FEA analysts, Mechnical Engineers, Materials and Polymer Scientists; Professional Engineers; Chemists; Paint and Coating Specialists; and NACE (National Association of Corrosion Engineers) Certified Corrosion Engineers, Materials Selection/Design, Coatings and Cathodic Protection Specialists. By combining the right equipment with the right staff, rapid and accurate determinations of the causes of failure can be made.

Walter Gretz, Debra Riley and Dr. Zee Discussing a Failure Analysis Project

On-site Inspection & Investigations

Our certified team of inspectors can perform non-destructive testing on project sites to evaluate the integrity of large structures.  Our team has performed such analyses nation and worldwide, and will travel to your project site at a moments notice for emergency evaluations.  Such large structure evaluations have included off-shore oil platforms, wind power generation towers, concrete domes and stadiums, large underground cooling systems, and large elevated water towers. 

Typical Projects

Although Matco's work is vital to its clients, it is rarely seen by the public. Here are some examples of recent jobs in which Matco provided the timely, competent, customer-oriented engineering analysis that made the difference.

Corrosion Failures

The investigation of corrosion failures can be very complex, and usually requires multidisciplinary testing and analysis to determine the root cause of failure. The end determination must be able to be made with a high degree of certainty to ensure that proper replacement materials are selected and that the most effective corrosion control methods are used. Experience is surely the most important ingredient to look for when choosing a materials firm to handle your corrosion control and failure analysis needs.

Corrosion Engineering & Failure Analysis

Experienced PE, PhD Scientists, NACE Certified in Corrosion, Coating, Design , Materials Selection & Cathodic Protection Specialists who will solve your corrosion problems at both initial design stages and in service. Matco provides corrosion evaluation and failure analysis investigations for : (a) underground facilities (b) above ground facilities and (c) strcutres in marine environments. Matco can investigate corrosion or corroso -related failures using state of the art techniques.Reports will be generated detailing corrosion failure causes and recommended means of prevention.

• Corrosion evaluation, life expectancy determination and cathodic protection of underground pipe lines, water mains, electrical poles and transmission lattices
• Corrosion mapping, detection of "Hot Spots", cathodic protection of reinforced concrete structures
• Coating/Paint  Investigations
• Electrochemical EIS , DC and AC Testing - Determination of cathodic protection criteria for non-ferrous alloys and stainless steels
• On-site Evaluation of tanks and corrosion mitigation by protective coatings and internal or external Cathodic Protection
• Corrosivity determination of soil, water and determination of corrosion mitigation techniques
• On-site coating evaluation and selection of coatings for specific corrosive environments by EIS             

Failure Analysis: Metallurgical support for a major commercial airline fleet (US Airways) that includes failure analysis investigations, corrosion investigations, and quality control testing. Bridge and construction failure investigations are routinly performed at Matco.

Corrosion Engineering: Cathodic protection system design and installation for a submerged ocean tunnel for the off-loading facility of the largest liquified natural gas (LNG) process facility in the United States. Our certified team of corrosion investigators can perform testing to evaluate the integrity of pressure vessels. These include refineries, underground and above ground oil,  gas and chemical process facilities   Our team has performed such analyses nation and worldwide, and will travel to your project site at a moments notice for emergency evaluations.

Paint/Coating Analysis: On-site and laboratory investigation of paint delamination failures (flaking and peeling) on galvanized structural members of several major stadiums in the United States.

On-site Inspection: Our certified team of inspectors can perform non-destructive testing on project sites to evaluate the integrity of large structures.  Our team has performed such analyses nation and worldwide, and will travel to your project site at a moments notice for emergency evaluations.  Such large structure evaluations have included off-shore oil platforms, wind power generation towers, concrete domes and stadiums, large underground cooling systems, and large elevated water towers. 

Enviromental Testing: Comparative testing of the resistance of pharmaceutical labels to environmental stresses (MFG, Humidity, and QUV testing) for a major drug retailer to determine what labels held up the best.

The original prescription label with typical label text imprinted on stock is shown on the left, while the faded label after heat and humidity testing is shown on the right.

Fire Investigation: Same-day analysis of the effects of a truck fire on the superstructure of a major highway bridge to determine whether or not the highway could remain open.

Explosion Investigations: Failure analysis of a gas main explosion that caused casualities.

Power Plants: Failure analysis and remaining life determination of boiler components in the power industry.

Implant  Materials: Electrochemical corrosion evaluation and failure analysis of implant materials such as hips, knees, stents, etc. to improve products and performance.

Galvanized Steel: How its microstructure and galvanized layer chemistry affect its appearance and corrosion resistance. Prevention and evaluation of storage rust, cracking of galvanized layer, failure of painted galvanized steel. Cabinet salt spray testing, EIS testing of painted galvanized steel and metallurgical characterization tests are routinly performed for galavanized and painted galvanized steel panels.

Utility and Light Poles & Lattices: Inspection and evaluation of galvanized, corten and painted carbon steel utility, light poles/lattices. Failure analysis, fatigue investigations, protective coating evaluation, life expectancy determination, corrosion evaluation, underground, ground level and above ground were included in this investigations.

R&D: Research & Development of new materials, coatings and sensors for the pipeline, construction/chemical  industry.

Finite Element Analysis

The finite element method is a powerful numerical tool for analyzing mechanical components and systems. The representation of a component or system mathematically with finite element, generally involves a discretization of the structure into many small pieces, e.g. small brick-like elements (hence the name of the method).

The solution to the equations that govern the behavior of the structure is approximated on each and every brick. The collective effect of all the bricks is taken into account during a step that synthesizes the solutions for each brick to one solution valid for the entire structure. This global solution represents the solution to the equations that govern the structure's behavior. The finite element method provides an accurate tool to predict and evaluate component response, elastic or non-linear plastic, subjected to thermal and structural loads.

Thermal analyses may include convection, conduction, and radiation heat transfer, as well as various thermal transients and thermal shocks. Structural analyses may include all types of constant or cyclic loads, mechanical or thermal, along with non-linearities, such as opening/closing of contact surfaces, friction, and non-linear material behavior.  

Failure Analysis Team

Our team is comprised of certified and experienced personnel from a variety of technical disciplines including: mechanical engineering, cathodic protection, paint inspection, chemistry, metallurgy, and materials science.  We also have a vast array of laboratory and field testing equipment. All of Matco's testing equipment is calibrated on a routine basis in accordance with both national and international standards, and is ready to be put to use at a moment's notice.

Our team includes professional engineers, mechanical engineers, chemists, coating specialists and NACE Certified Materials Selection/ Design / Corrosion/Coating Specialists (*) includes:

                    Dr. M. Zee(*)                                             Mr. Geoff Rhodes (*)

                    Dr. Don Gibbon                                         Mr. Kevin Groll  (*)          

                    Dr. George Bayer                                      Ms. Debra Riley (*)

                    Mr. Joe Tureck                                          Mr. Ed Larkin

                    Mr. Ed MaCan, PE                                    Mr. Walter Gretz, PE

                    Dr. Kasraie, PE                                         Dr. Huping Xue

                    Dr. Bavarian                                              Mr. Jay Metha 

An illustrated formal report documents the results of the investigation. If necessary, Matco personnel can usually be on site almost immediately when requested during emergency situations.

Matco Associates is conveniently located halfway between the Pittsburgh International Airport and downtown Pittsburgh, and only a few yards from an exit on the Parkway West (I-279/US22-30), so reaching our laboratories and offices is quick and easy. Please feel free to call to discuss your problems and arrange a visit to our laboratories.  Matco has an office and laboratory in Florida/ Miami/ Fort Lauderdate area. You can always call Matco at 1-800-221-9090 or Cell 412-952-8441 if you need emergency rush job.