SOR 1223 Failure Analysis and Reliable Design

Failure analysis should explain not only how a component failed, but why the failure occurred in the first place. Mojan and Enrico explore how material science and reliability engineering work together to uncover root causes and prevent recurring problems. They compare fracture analysis in metals and polymers, discuss the challenges of interpreting damage mechanisms, and examine how material characterization techniques can reveal hidden defects. The conversation also highlights a critical manufacturing challenge: components made from the same material and geometry can behave differently because of processing conditions. The episode shows why effective failure analysis requires combining physical evidence, statistical analysis, and manufacturing knowledge rather than relying on a single observation.