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MATCO Services, Inc. is a leading independent consulting, engineering, and testing firm specializing in the fields of failure analysis, inspection, corrosion, metallurgical engineering, cathodic protection systems, materials selection, 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 included bridge , mechanical equipment; superheater & boiler tubes; wire cables; bridge components, 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:
We boast a fully equipped lab with state-of-the-art equipment, including:
- Scanning Electron Microscope equipped with Energy-Dispersive X-ray Spectroscopy to evaluate surfaces at high magnifications for fracture modes, defects, contaminants and corrosion products;
- FTIR spectrometer for identification of organic contaminants, oils, paints, and fibers;
- Complete array of light microscopes with a computerized Image Analysis System for quantitative evaluation of microstructures
- Full corrosion AC/DC polarization testing
- Electro-Impedance Spectroscopy
- Cabinet testing with MFG capabilities.
- Full range of surface analysis instruments (AES, XPS, SIMS), especially valuable for analysis of bonding problems
- FEA analysis capabilities.
This equipment allows the MATCO team to establish the all-important link between failure mechanisms, properties, and microstructures. MATCO's well equipped lab and our professional staff can deliver on-target solutions to all of your testing, analysis, and materials selection needs. Our team has performed such analyses nation and worldwide, and will travel to your project site at a moments notice for emergency evaluations.
The other half of the battle is having the right staff. MATCO ‘s staff includes experienced PhD-level Metallurgists, FEA analysts, Mechanical 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.
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.
Corrosion Engineering & Failure Analysis
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.
MATCO has experienced PE, PhD Scientists, NACE Certified 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 corrosion-related failures using state of the art techniques. Reports will be generated detailing causes of corrosion failure 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
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
Electrochemical Corrosion Testing of Three Types of Diffusion Coating
Welding Engineering Services
1. Weld Procedures
MATCO can provide a full-time Welding Engineer at your facility to develop and document required welding procedures. Documentation will be on your company letterhead, as required by code. MATCO will arrange for full testing and evaluation of the welded test plates, including chemical, physical and non-destructive means of study. Typical means of testing:
Radiographic, ultrasonic, magnetic particle, dye penetrant inspection.
Microscopic and metallurgical examination.
Corrosion and stress-corrosion testing.
Tensile tests, bend tests, charpy impact tests and hardness tests.
Prepare Procedure Qualification Records (PQR's) and Weld Procedure Specifications (WPS's).
2. Welder Testing
MATCO can provide a full-time welding engineer at your facility to test welders to the applicable code. Test plates will be evaluated by destructive and/or non-destructive methods.Results will be documented on your company letterhead as required by code.
3. Failure Analysis
MATCO can investigate weld or weld-related failures using state of the art techniques.Reports will be generated detailing failure causes and recommended means of prevention.
4. Vendor Audits
A. MATCO can provide personnel to conduct audits of vendors and/or sub-contractors regarding weld- related activities or projects. For instance, compliance with ISO 9000 could be ascertained.
Macroetch of a Weld Structure
Partial list of Services Available for Welded Components
- Failure analysis of welded components
- Corrosion failure analysis of welds and welded components
- Metallography/On-site metallography
- Hardness testing/On-site hardness testing
- Microhardness testing-Vickers and Knoop
- Macroetch inspection
- Sensitization of austenitic stainless steels per ASTM A262
- Sensitization of ferritic stainless steels per ASTM A763
- Chemical analysis of base metals for weldability and selection of preheat and post heat temperatures
- Mechanical testing
- Scanning electron microscopy
- Chemical analysis of weld deposits
- Seven gage delta ferrite determination in 300 series stainless steel welds
MATCO looks forward to discussing your welding issues to see what might be done to rectify your real cusp type problem in the welding area.
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.
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 routinely 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.
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 Services? 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 Services, 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.
MATCO Services 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 Lauderdale area. You can always call MATCO at 1-800-221-9090 or Cell 412-952-9441 if you need emergency rush job.