One of the main objective of the course is to familiarize the students with the fundamental concepts of  failure analysis procedure and to provide an insight view on how the materials behave in real industrial conditions. Thus, this course provides a description on the most expected material failures (Corrosion, High temperature, Mechanical failures) supported by real examples – case studies from industry- that are presented and analyzed both theoretically and in the laboratory.

1.  Mechanisms, causes and analysis of failures.

•  Introduction
• Overview of failure mechanisms
• Causes of failures
• Methodology of failure analysis

2. Corrosion failures:

• Uniform corrosion,
• Galvanic corrosion,
• Pitting, crevice,
• Selective corrosion
• Stress corrosion cracking
• Hydrogen embrittlement

3.  High Temperature Failures:

• Oxidation
• Carburization
•  Metal dusting
• Thermal Shock
• Sulfidation
• Fuel Ash corrosion

4. Mechanical Failures:

• Creep
• Fatigue
• Wear
• Plastic deformation
• Brittle fracture
• Corrosion Fatigue

5.  Effects on engineering design.

• Design to optimize resistance to: fatigue, creep, corrosion

Laboratories:
1. Example of failure due to Galvanic Corrosion.
2. Example of failure due to Pitting Corrosion.
3. Example of failure due to Crevice Corrosion.
4. Example of failure due to Stress Corrosion Cracking.
5. Example of failure due to Hydrogen Embrittlement.
6. Example of failure due to Hot Corrosion.
7. Example of failure due to Thermal Shock.
8. Example of failure due to Sulphidation.
9. Example of fatigue failure. Laboratory analysis.
10. Example of failure due to brittle fracture.
11. Example of Creep Failure. Basic Creep Calculations.

Suggested Literature:
• G.N. Haidemenopoulos, A. D. Zervaki, Failures Of Mechanical Components and
Construction, Tziolas, 2024. (in Greek)
• D.R.H. Jones, Engineering Materials 3 ‐ Failure analysis, Pergamon Press, 1993.
• D. Wulpi, Understanding How Components Fail, ASM, 1999.
• A. K. Das, Metallurgy of failure analysis, Mc Graw‐Hill, 1996.
• D. Broek, The practical Use of Fracture Mechanics, Kluwer Academic Press, 1988.
• J. Knott, P. Whithey, Fracture Mechanics. Worked Examples, IOM, 1979.
• A. Shukla, Practical Fracture Mechanics in Design, Second Edition, Taylor and Francis, 2004.
• J. A. Collins, Failure of Materials in Mechanical Design: Analysis, Prediction, Prevention, Wiley‐Interscience, 2007.
• V. J. Colangelo and F. A. Heiser, Analysis of Metallurgical Failures, John Wiley & Sons, 1987.
• A. J. McEvily, Metal Failures: Mechanisms, Analysis, Prevention, Wiley‐Interscience, 2001.

Handbooks
• ASM Handbook, 9th edition, Vol.11 Failure Analysis and Prevention, ASM, 2002
International, Materials Park, OH, USA, 1986.
• Handbook of Case Histories in Failure Analysis, Vol.1 and 2, ASM, 1992

CD‐ROMs
• Failure Analysis Library, ASM International, 2000

Internet Site
• ASM Failure Analysis Center Online, www.asminternational.org/materialsinfo

Related academic journals: 
• Journal of Failure analysis and prevention, Editor: McIntyre R. Louthan Jr., ASM, ISSN 1547‐7029
• Engineering Failure analysis, Elsevier, Editor D.R.H. Jones, ISSN 1350‐6307
• Case Studies in Engineering Failure Analysis, ISSN2213-2902

Greek

Lectures and Case Studies