Abstract 
Considerable developments in metal failure analysis techniques and reliability are emerging with legal community acceptance of traditional methodologies in mechanical tests and nondestructive tests.   Mechanical tests assess metal properties such as ductility, tensile strength, toughness and weldability.  Nondestructive tests provide surface and sub-

surface flaw detection, location and features.   Verification of metal properties by actual tests is just a good policy for the Forensic Engineer. 

Introduction
One test is better than a thousand expert opinions.   The seasoned Forensic Engineer knows that quality satisfies design and quality cannot be inspected into a part.   During manufacturing a metal item, the responsibility of management is to evaluate all costsand benefits of production activities, including exposure to product-liability issues because of their decisions.  

Extending service-life and fitness-for-service analyses are achieving wider interest by governments, engineers and the legal community.  The economic advantages of avoiding business interruptions, personal injuries, and extending service life justify the use of traditional mechanical tests and nondestructive tests.  The Forensic Engineer often makes decisions using precise fundamental principles, while answers to ethical questions are often a shade of gray.

The Forensic Engineer knows to accurately examine failed metals, the designer’s intent must be understood, then confirm that the proper metals and processes were used.  The experienced Forensic Engineer also applies many bits of practical information that are seldom taught in schools or found in handbooks.

Many industries use mechanical tests and nondestructive tests to eliminate defective incoming material from manufacturing processes.   During production, routine metal tests are used to check for flaws while processing an item, eliminating wasted time and material when defects are located at the earliest possible stage in the cycle.  When the part is finished, customer satisfaction is the primary goal of all interim metal tests.

Metal classifications include appearance, dimensions, weight, magnetic properties, chemical composition, mechanical properties, thermal coefficients, corrosion resistance, electrical conductivity, and others. There are numerous methods used to identify and confirm that the proper metal, without defects, is used in the item being produced.

Personnel performing mechanical tests and nondestructive tests need to be qualified by education, experience and routine training.  Inspectors must pass written examinations and hands-on proficiency tests to obtain recognized certification that is acceptable in the legal community.

During an examination, the Forensic Engineer must consider the statistical probability of flaw detection, which is defined as the probability that, using a given inspection procedure, a trained inspector will detect a flaw if it exists.   Read more ...

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