About Us

Hot Crack | Lamellar Tearing | Lack of Penetration (LOP) and Lack of Fusion( LOF) | Weld Decay Stainless Steel (Sensitization)

Welded, Brazed, Soldered or Bolted Joint Failures

The role of joints whether welded, brazed, soldered or bolted is the most critical aspect to hold any assembly together. Joints are usually the weakest link in the total assembly and decide the overall integrity of equipment. Joint failures are as specific as the nature of joining process. Welded joints can fail due to lapses during the welding parameters, operational skills or merely because of properties inferior to base metal. ITS personnel has analyzed welded joint failures from a variety of weaknesses such as cracking, lack of fusion, undercuts, faulty fit ups, improper pre heat, or stress relieving, wrong consumables, to name a few. Similarly we have come across numerous bolted joint failures and studs that have rolling defects, machining lapses, or dirty material. Brazed or solder joints made from deficient chemistries or with deficient geometries have caused numerous joint failures that we have recorded. ITS personnel has analyzed soldered joint failures that have lead to chronic failure of bus Radiators and generators of buses. We have been retained by various legal and private parties as an independent body to carry out failure analysis for settling disputes. ITS often retained by fastener manufacturers to carry out testing and development work of for the purpose quality improvement or cost optimization.

Our approaches for failure analysis may include

  • Analysis of the base and joining material
  • Parameters under which joint was made
  • Study of component history
  • Visual examination/fractography
  • Checking profiles of the joint
  • NDT including ultrasonic and radiography
  • Microscopic examination of material samples
  • Mechanical Test as per applicable specifications
  • Hydrogen Embrittlement tests
  • Scanning Electron Microscopy (SEM) and Energy Dispersive X-Ray Spectrometry (EDS)

Based on all our observations and analysis, the client is provided with the detailed report that is conclusive, accurate and well illustrated for technical and non technical readers.

 

Crack in a soldered joint

Crack in a soldered joint of bus radiator core that originated at a solder deficiency.

Some of the Joint failure analysis carried out recently include:

  • Joint failure of a dredger base due to faulty weld profile
  • Joint failure of a radar of a tug boat due to deficient design
  • Joint failure of a passenger ferry hull because of lack of quality control
  • Chronic solder joint failure of radiators on a fleet of buses due to manufacturing deficiencies
  • Premature joint failure of generators soldered using weak joint material.

 

Stainless Steel Slip

A two inch stainless steel slip-on flange weld that cracked primarily because of
poor fit up during welding.