Despite careful manufacture, design and operation, components repeatedly fail. The analysis of fractures and cracks represents a special case of the damage analysis d. Here, the focus is often placed specifically on identifying the cause by means of systematic analyses. The VDI guideline 3822 “Damage Analysis” or DIN EN 60812 “Failure Mode and Effect Analysis (FMEA)” provide a good overview of the general procedure. optical, physical or chemical test methods are used to record, compare and simulate the condition. Thus the probable origin of the damage can be determined or limited. The procedure must be scientifically exact, systematic and comprehensive in order to be able to consider and evaluate all (possible) influencing factors in an appropriate manner.

The entire production process can be rolled up or only the damaged component can be evaluated in comparison to “good samples”. Information from the field, from producers and users is helpful and sometimes essential. At WZR ceramic solutions GmbH, the knowledge of material properties and material behaviour is given by more than 20 years of experience and the assessment by trained experts.

After the analysis, an optimisation of the product or the process can be carried out at the customer’s request in order to prevent further damage.

image: vertical cracks (marked pink) on a ceramic part.

In the picture shown above, in addition to optical considerations, various crack and fracture causes of the components must be considered from the outset: Mechanical stress or lack of strength, cracks due to thermoshocks, thermal expansion or surface treatment. In addition, the stress state of the components would be a potential cause of damage.

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Figure: SEM microstructural overview of the cross-section of a FF material after use