Level I - Failure Mode Identification

Purpose and Scope

This course is designed to provide the experienced maintenance and reliability professional with the required knowledge and skills to determine why a machine component failed and how to prevent a future failure.  The skills required to identify the physical mechanisms causing shafts, bolts, bearings, gears, belts, couplings, and other machinery parts to fail are presented in this course. Inspection and identification techniques are practiced by the participants.

Hands on exercises and worksheets, using a variety of failed parts, will be analyzed by participants to develop inspection and identification competencies.  How to identify fatigue fracture, brittle fracture, ductile fracture, stress concentrations, types of corrosion, rolling contact fatigue, and wear, is demonstrated. Participants spend approximately 50% of the class time using a variety of failed parts, case studies, and worksheets to learn and develop inspection and identification skills.


After completing this course, participants will be able to identify the physical mechanisms that caused a component to fail.   They will be able to accurately identify and describe:

• Fatigue failures: bending, tension, torsion, and rolling contact
• Overload failures: brittle and ductile
• Abrasive and adhesive wear
• Stress concentrations
• Direction and type of forces that caused a failure
• Different forms of corrosion and basic countermeasures
• The effect of material properties on failure modes
• Failure modes of: shafts, journals, bolts, gears, bearings, and structures

Upon returning to work, participants will be expected to immediately utilize the inspection and identification skills taught in the class to target the physical roots of equipment failures and describe countermeasures needed to prevent the same or similar failures from occurring.
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