The first step in failure analysis is investigating the failure to collect information. The sequence of steps for information gathering in a failure investigation are:
# Collection information about the circumstances surrounding the failure and selection of specimens
# Preliminary examination of the failed part (visual examination) and comparison with parts that have not failed
# Macroscopic examination and analysis and photographic documentation of specimens (fracture surfaces, secondary cracks, and other surface phenomena)
# Microscopic examination and analysis of specimens (fracture surfaces)
# Selection and preparation of metallographic sections
# Microscopic examination and analysis of prepared metallographic specimens
# Nondestructive testing
# Destructive/mechanical testing
# Determination of failure mechanism
# Chemical analysis (bulk, local, surface corrosion products, deposits or coatings)
# Identify all possible root causes
# Testing most likely possible root causes under simulated service conditions
# Analysis of all the evidence, formulation of conclusions, and writing the report including recommendations