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  • 1.  Failure analysis (Additive manufacturing v. traditional)

    Posted 01-23-2023 09:03

    How will failure analysis of additive manufactured materials differ from traditional failure analysis?

    John Merrill
    Principal Engineer
    Matthews NC
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  • 2.  RE: Failure analysis (Additive manufacturing v. traditional)

    Posted 01-28-2023 10:02
    Thoughts? @Daniel Dennies, @Elvin Beach or @Larry Hanke


    Carrie Hawk
    ASM International
    Community Engagement Specialist

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  • 3.  RE: Failure analysis (Additive manufacturing v. traditional)

    Posted 01-30-2023 11:52
    History of the part is always important but often hard to obtain.  AM parts will raise this up a notch as lot traceability will likely include small batches and potentially even harder to trace back to any raw material, tooling or operator influence.  Porosity of the finished material will also become more important to characterize.

    Gary Shade
    Manager Product Analysis (ESG)
    Colorado Springs CO
    (719) 465-6579

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  • 4.  RE: Failure analysis (Additive manufacturing v. traditional)

    Posted 01-31-2023 09:15

    The following ASM Handbook articles may be of interest

    Daniel P. Dennies, S. Lampman, Failures Related to Metal Additive Manufacturing, Analysis and Prevention of Component and Equipment Failures, Vol 11A, ASM Handbook, Edited By Brett A. Miller, Roch J. Shipley, Ronald J. Parrington, Daniel P. Dennies, ASM International, 2021, p 250–265,

    M. Brennan, J.S. Keist, T.A. Palmer, Defects in Metal Additive Manufacturing Processes, Additive Manufacturing Processes, Vol 24, ASM Handbook, Edited By David L. Bourell, William Frazier, Howard Kuhn, Mohsen Seifi, ASM International, 2020, p 277–286,


    Scott Henry
    Senior Content Engineer
    ASM International

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  • 5.  RE: Failure analysis (Additive manufacturing v. traditional)

    Posted 01-31-2023 09:51
    Hi John,
    I think that the failure analysis methodology of AM parts will not differ from traditional. The fracture surfaces may show sometimes new phases since we know now that AM is capable to produce phases that are usually not found in traditional materials, but this could be characterized by the methods used for failure analysis i.e. SEM/EDAX, and by microstructure observations on cut-ups from failed parts. If you are familiar with welding microstructure and already made failure investigations on welded components, you'll be able to see that it'll help for the investigation on AM pieces.
    Hope this help.

    Nihad Ben Salah
    NBS- M&P Consulting

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