failure-analysis

# Failure Analysis Skill ## Purpose The Failure Analysis skill provides systematic methodology for investigating mechanical component failures, enabling root cause identification through fractography, metallography, stress analysis, and structured problem-solving approaches. ## Capabilities - Fractography interpretation (SEM, optical) - Metallographic examination guidance - Root cause analysis frameworks (5-Why, Fishbone) - Failure mode identification (fatigue, corrosion, overload) - Stress analysis correlation to failure location - Chemical analysis interpretation - Corrective action development - Failure analysis report generation ## Usage Guidelines ### Investigation Process #### Phase 1: Evidence Preservation 1. **Documentation** - Photograph failed components as-received - Document orientation and assembly position - Record operating conditions at failure - Preserve all fragments 2. **Chain of Custody** - Log all handling - Secure storage - Controlled access - Document any cleaning or cutting #### Phase 2: Visual Examination 1. **Macroscopic Features** | Feature | Indication | |---------|------------| | Beach marks | Fatigue | | Chevron marks | Brittle fracture | | Shear lips | Ductile overload | | Corrosion products | Environmental attack | | Wear patterns | Tribological failure | 2. **Fracture Origin** - Identify initiation site - Look for stress concentrations - Check for material defects - Document ...