Failure Analysis

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 included 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.

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.

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. Our projects have taken us from Aloha Stadium in Hawaii to Alyeska Ski Resort in Alaska; from bridges in Pennsylvania to titanium structures in Tokyo, Japan.

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 P.E., Ph.D. 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.

Comprehensive reports that indicate root cause and mode of failure are provided in clearly written language.  Since these reports are generated based on factual data that relies on test results to determine the root cause and mode of a materials failure rather than on opinion, MATCO reports are renowned for their ability to hold up in a court of law where testimony may be required.  Below are examples of failure analysis projects performed at MATCO Services.

• 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

If necessary, MATCO personnel can usually be on site almost immediately when requested during emergency situations.  A description of some of the types of projects that are performed are indicated below.

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. Our projects have taken us from Aloha Stadium in Hawaii to Alyeska Ski Resort in Alaska; from bridges in the Bahamas to titanium structures in Tokyo, Japan and damage evaluation of hurrican in Florida. This project included roofing, siding, paint and internal water damage for a large structure.

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

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.

Below is a listing of the types of failure analysis projects that are performed at MATO Services, Inc.

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, P.E. (*)

Dr. Bayer                                                  Ms. Debra Riley (*)

Mr. Marty Latona                                   Mr. Ed Larkin

Dr. Kasraie, P.E.                                       Mr. Walter Gretz, P.E.

We Value Our Customers... Throughout the years, we have noticed that much of our business comes from repeat customers. Our expertise and well-equipped lab can account for much of this, but we believe there is something more to it. We attribute it to the fact that we promote an open and friendly environment that is never too busy to meet your needs. At MATCO, we value your business whether you are a large corporation or a small enterprise. We will provide you with the attention you need and deserve. We invite you to visit us and get to know our staff, and share in the learning experience.

Why Choose MATCO? As one of the premier testing and failure analysis firms featuring state of the art equipment, MATCO is able to provide a unique and diverse blend of services. Thousands of investigations have been performed at MATCO, ranging from jet engines and boiler tubes, to computer components and implants. Projects are not only conducted on your schedule from initiation to completion with competent and experienced personnel, and conducted in a discrete manner that ensures confidentiality as well.