Root Cause Analysis, Fracture Investigation & Material Failure Diagnostics for Metallic and Non-Metallic Materials — Oil & Gas, Aerospace, Industrial and Manufacturing Applications

  Failures don’t just happen — they leave evidence. Every fracture surface, every corrosion deposit, every degraded seal, every delaminated composite panel tells a story. As one of the leading failure analysis laboratories in UAE, METS Lab Abu Dhabi applies a systematic, evidence-based investigation methodology to uncover the true root cause of component, equipment, and structural failures — across both metallic and non-metallic materials — before the same failure repeats itself. Our multidisciplinary failure analysis team combines advanced analytical instrumentation, deep materials science expertise, and internationally recognized investigation methodologies including ASME, ASTM, NACE, ISO, and ASM Handbook frameworks. Whether you are dealing with an unexpected field failure, a warranty claim, a quality incident, or a catastrophic equipment loss — in metals, polymers, elastomers, composites, ceramics, coatings, or concrete — we deliver forensic-quality findings backed by scientific rigor. We find the cause. You get the solution — and the documented evidence to act on it.

Our Core Failure Analysis Services Include

• Root Cause Analysis (RCA) of Metallic Component Failures
• Root Cause Analysis (RCA) of Non-Metallic Component Failures (Polymers, Elastomers, Composites, FRP, Ceramics, Coatings & Concrete)
• Fracture & Fractography Investigation
• Corrosion & Chemical Degradation Failure Analysis
• Fatigue & Overload Failure Investigation
• Wear, Erosion & Abrasion Failure Assessment
• Manufacturing Defect & Process-Related Failure Investigation
• Polymer Degradation, Crazing & Environmental Stress Cracking Analysis
• Elastomer Swell, Extrusion & Explosive Decompression Failure Investigation
• Composite Delamination, Fibre-Matrix Debonding & FRP Failure Investigation
• Coating & Surface Treatment Failure Investigation
• Weld Failure Analysis & Joint Integrity Assessment
• Litigation Support & Expert Witness Reporting

 

Section A: Metallic Material Failure Analysis

Fracture & Fractography Investigation

Fracture surfaces are one of the most information-rich evidence sources in engineering failure investigation. The pattern, texture, and morphology of a fracture surface reveal the failure mode — whether brittle, ductile, fatigue, intergranular, or transgranular — and provide critical data about the stress state, loading history, and environmental conditions at the time of failure. At METS Lab Abu Dhabi, we perform detailed scanning electron microscopy (SEM) fractography combined with macro-visual examination to systematically characterize fracture surfaces and identify the origin, propagation path, and final overload zone. Our fracture investigation methodology follows:

• ASM Handbook Volume 11 — Failure Analysis and Prevention: the authoritative reference for systematic fracture investigation methodology, fractographic feature interpretation, and failure mode classification
• ASTM E620 — Standard Practice for Reporting Opinions of Technical Experts — governing the structure and objectivity of failure analysis reporting
• ASTM E1245 — Standard Practice for Determining the Inclusion or Second-Phase Constituent Content of Metals by Automatic Image Analysis
• ASME Boiler & Pressure Vessel Code (BPVC) Section V & VIII — for fracture assessment of pressure-containing components
• BS 7910 — Guide to Methods for Assessing the Acceptability of Flaws in Metallic Structures — fracture mechanics-based fitness-for-service assessment

Corrosion Failure Analysis

Corrosion is responsible for an estimated 25–30% of all engineering failures globally. Identifying the precise corrosion mechanism — whether uniform, galvanic, pitting, crevice, intergranular, stress corrosion cracking (SCC), microbiologically influenced corrosion (MIC), or erosion-corrosion — is essential for implementing effective corrective action. At METS Lab Abu Dhabi, we combine visual examination, SEM/EDS elemental analysis, metallographic cross-sections, and chemical characterization to fully document corrosion failure mechanisms. Our methodology is aligned with:

• ASM Handbook Volume 13A — Corrosion: Fundamentals, Testing, and Protection — the primary reference for corrosion mechanism identification and failure analysis methodology
• ASM Handbook Volume 13B — Corrosion: Materials — corrosion behavior of specific alloy systems and material groups
• NACE SP0106 — Control of Internal Corrosion in Steel Pipelines and Piping Systems
• NACE TM0177 — Stress Corrosion Cracking and Sulfide Stress Cracking Testing in H₂S environments
• ISO 8044 — Corrosion of Metals and Alloys — Basic Terms and Definitions
• ASTM G161 — Standard Guide for Corrosion-Related Failure Analysis

Fatigue & Overload Failure Investigation

Fatigue is responsible for an estimated 50–90% of all mechanical failures. Fatigue failures develop progressively from small cracks under cyclic loading well below the material’s yield strength, often with no visible warning until sudden final fracture. Distinguishing between fatigue and overload, identifying crack initiation sites, and establishing loading history is critical for corrective action. Our methodology follows:

• ASM Handbook Volume 19 — Fatigue and Fracture: fatigue mechanisms, crack growth analysis, and fracture mechanics
• ASTM E647 — Standard Test Method for Measurement of Fatigue Crack Growth Rates
• ASTM E1820 — Standard Test Method for Measurement of Fracture Toughness
• ASME BPVC Section VIII Div. 2 — Fatigue design and assessment of pressure vessels
• BS 7608 — Fatigue Design and Assessment of Steel Structures
• ISO 12107 — Metallic Materials — Fatigue Testing — Statistical Planning and Analysis of Data

Wear, Erosion & Abrasion Failure Investigation

Wear and erosion failures account for significant losses in rotating equipment, valve components, pump internals, pipeline systems, and cutting tools. The wear mechanism — whether adhesive, abrasive, erosive, fretting, or cavitation erosion — determines the appropriate corrective action. At METS Lab Abu Dhabi, we perform detailed surface morphology analysis, cross-sectional metallography, and hardness profiling to characterize wear damage and identify the governing mechanism. Our investigation follows:

• ASM Handbook Volume 18 — Friction, Lubrication, and Wear Technology: the definitive reference for wear mechanism identification
• ASTM G40 — Standard Terminology Relating to Wear and Erosion
• ASTM G73 — Liquid Impingement Erosion Testing
• ASTM G76 — Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets
• ASTM G77 — Ranking Resistance of Materials to Sliding Wear Using Block-on-Ring Wear Test
• NACE SP0291 — Erosion-Corrosion in Oil and Gas Environments

Manufacturing Defect & Process-Related Failure Investigation

Many in-service failures trace back to material or manufacturing defects introduced during production — including improper heat treatment, forging laps, casting porosity, inclusion stringers, decarburization, or incorrect alloy composition. At METS Lab Abu Dhabi, we apply chemical analysis, metallographic examination, hardness testing, and non-destructive evaluation to systematically trace failure origins to manufacturing or process sources. Our investigation follows:

• ASM Handbook Volume 11 — Failure Analysis and Prevention: manufacturing defect classification and investigation methodology
• ASTM A370 — Standard Test Methods and Definitions for Mechanical Testing of Steel Products
• ASTM E3 — Standard Guide for Preparation of Metallographic Specimens
• ASTM E407 — Standard Practice for Microetching Metals and Alloys
• ISO 4967 — Steel — Determination of Content of Non-Metallic Inclusions — Micrographic Method
• ASME BPVC Section IX — Welding, Brazing, and Fusing Qualifications

Weld Failure Analysis & Joint Integrity Assessment

Weld failures are among the most consequential in pressure vessels, pipelines, structural components, and offshore equipment. Common modes include hydrogen cracking, solidification cracking, lamellar tearing, lack of fusion, and fatigue from weld toe stress concentrations. Our investigation methodology is aligned with:

• AWS D1.1 — Structural Welding Code — Steel: acceptance criteria and defect classification for structural welds
• ASME BPVC Section IX — Welding Procedure and Welder Qualification requirements for pressure equipment
• ISO 6520-1 — Welding and Allied Processes — Classification of Geometric Imperfections in Metallic Materials
• ISO 5817 — Fusion-Welded Joints in Steel, Nickel, Titanium and their Alloys — Quality Levels for Imperfections
• NACE SP0169 — Control of External Corrosion on Underground or Submerged Metallic Piping Systems
• BS 7910 — Fracture mechanics assessment of weld flaws and fitness-for-service evaluation

Section B: Non-Metallic Material Failure Analysis

Non-metallic materials — including polymers, elastomers, fibre-reinforced composites, FRP piping and vessels, ceramics, coatings, and concrete — are critical components across oil and gas, chemical processing, aerospace, construction, and medical industries. Their failure mechanisms differ fundamentally from metals and require specialist analytical techniques and dedicated investigation standards. METS Lab Abu Dhabi provides comprehensive failure investigation across all major non-metallic material categories.

Polymer & Plastic Component Failure Investigation

Polymers and engineering plastics are extensively used in seals, gaskets, pipe liners, valves, cable insulation, medical devices, and consumer products. Polymer failures often involve complex time-dependent mechanisms including creep, environmental stress cracking (ESC), chemical attack, UV degradation, thermal oxidation, and fatigue crack propagation through viscoelastic materials. Correct identification of the governing degradation mechanism is essential for material reselection and design correction. At METS Lab Abu Dhabi, our polymer failure investigation covers:

• ASM Handbook Volume 11B — Characterization and Failure Analysis of Plastics: the primary reference for systematic plastic failure investigation methodology and degradation mechanism identification
• ASTM D5947 — Standard Test Methods for Physical Dimensions of Solid Plastics Specimens
• ASTM D638 — Tensile Properties of Plastics — residual strength assessment of failed plastic components
• ASTM D790 — Flexural Properties of Unreinforced and Reinforced Plastics — stiffness and brittleness evaluation
• ASTM D1693 — Environmental Stress-Cracking of Ethylene Plastics — ESC failure identification and assessment
• ASTM D5229 — Moisture Absorption Properties and Equilibrium Conditioning of Polymer Matrix Composite Materials
• ISO 527 — Plastics — Determination of Tensile Properties — residual property measurement on failed specimens
• ISO 179 — Plastics — Determination of Charpy Impact Properties — toughness assessment and embrittlement characterization

Key failure modes investigated in polymer components include: brittle fracture due to chemical attack or UV embrittlement, environmental stress cracking (ESC) caused by incompatible chemicals or residual stress, creep deformation and stress relaxation, oxidative degradation, hydrolytic degradation of polyesters and polyamides, and fatigue crack initiation at stress concentrations or weld lines.

Elastomer & Rubber Seal Failure Investigation

Elastomeric seals, O-rings, gaskets, packers, and diaphragms are critical to pressure containment and fluid isolation in oil and gas, chemical processing, and industrial systems. Elastomer failure mechanisms are highly complex and environment-specific, encompassing volume swell from chemical absorption, compression set loss, explosive decompression damage, hardening from oxidation or thermal ageing, softening from plasticizer extraction, and tearing from mechanical overload or extrusion. At METS Lab Abu Dhabi, we perform complete characterization of elastomer failure through physical property measurement, chemical identification, and microscopic examination. Our investigation follows:

• NORSOK M-710 — Qualification of Non-Metallic Sealing Materials — the primary standard for elastomer qualification and failure assessment in subsea and downhole environments
• NACE TM0187 — Evaluating Elastomeric Materials in Sour Gas Environments — chemical attack and physical property change assessment in H₂S-containing service
• ISO 23936-2 — Non-Metallic Materials in Contact with Oil and Gas Production Media — Elastomers — qualification and failure assessment framework
• ASTM D471 — Standard Test Method for Rubber Property — Effect of Liquids: volume swell, mass change, and property retention measurement
• ASTM D2240 — Rubber Property — Durometer Hardness: hardness mapping pre- and post-failure
• ASTM D395 — Rubber Property — Compression Set: assessment of permanent deformation in failed seals
• ASTM D412 — Vulcanized Rubber and Thermoplastic Elastomers — Tension: tensile strength and elongation retention in failed specimens
• ISO 37 — Rubber, Vulcanized or Thermoplastic — Determination of Tensile Stress-Strain Properties

Key failure modes investigated in elastomers include: explosive decompression (ED) damage from rapid pressure release in gas service; extrusion damage from excessive clearance gaps under pressure; chemical swelling and softening from incompatible fluid exposure; thermal hardening and oxidative cracking from elevated temperature service; compression set failure resulting in inadequate sealing force; and tearing or abrasion from mechanical overload or dynamic service conditions.

Fibre-Reinforced Composite & FRP Failure Investigation

Fibre-reinforced polymer (FRP) composites and glass/carbon fibre reinforced plastics are widely used in pipelines, pressure vessels, structural panels, aerospace structures, and marine components. Composite failure is inherently complex, involving multiple simultaneous damage mechanisms including fibre fracture, matrix cracking, fibre-matrix interface debonding, interlaminar delamination, impact damage, and moisture-induced degradation. At METS Lab Abu Dhabi, we investigate composite failures through a combination of macro visual examination, cross-sectional microscopy, SEM fractography, and mechanical testing of retained material. Our investigation methodology is aligned with:

• ASTM D3171 — Constituent Content of Composite Materials — fibre volume fraction and void content assessment in failed laminates
• ASTM D2290 — Apparent Hoop Tensile Strength of Plastic or Reinforced Plastic Pipe by Split-Disk Method — for FRP pipe failure assessment
• ASTM D2105 — Axial Tensile Properties of Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Tube
• ASTM D2412 — Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading
• ASTM D5573 — Classifying Failure Modes in Fibre-Reinforced-Plastic (FRP) Joints — adhesive and cohesive failure mode identification
• ASTM C1557 — Tensile Strength and Young’s Modulus of Fibres
• NACE TM0298 — Evaluating the Compatibility of FRP Pipe and Tubulars with Oilfield Environments — chemical attack and degradation assessment
• ISO 14130 — Fibre-Reinforced Plastic Composites — Determination of Apparent Interlaminar Shear Strength — for delamination failure assessment
• ISO 15024 — Mode I Interlaminar Fracture Toughness of Unidirectional Fibre-Reinforced Polymer Laminates

Key failure modes investigated in composites and FRP include: interlaminar delamination from impact, cyclic loading, or moisture ingress; fibre-matrix debonding from chemical attack or thermal cycling; matrix cracking from overload or fatigue; fibre fracture from tensile overload; blistering and liner failure in FRP piping from chemical permeation; and UV-induced surface degradation.

Coating & Lining Failure Investigation

Organic and inorganic coatings and linings protect metallic substrates from corrosion, chemical attack, and mechanical damage in pipelines, vessels, tanks, offshore structures, and downhole equipment. Coating failure results in accelerated substrate corrosion, production contamination, and unplanned maintenance interventions. At METS Lab Abu Dhabi, we investigate coating failures through adhesion testing, cross-section microscopy, SEM/EDS analysis, and FTIR chemical identification to determine whether failure originated from application defects, environmental attack, mechanical damage, or substrate preparation issues. Our investigation methodology follows:

• ASTM D4541 — Pull-Off Strength of Coatings Using Portable Adhesion Testers — adhesion measurement pre- and post-exposure
• ASTM D714 — Evaluating Degree of Blistering of Paints — blister density and size classification
• ASTM D610 — Evaluating Degree of Rusting on Painted Steel Surfaces — substrate corrosion breakthrough assessment
• NACE TM0185 — Evaluation of Internal Plastic Coatings for Corrosion Control of Tubular Goods in Aqueous Flowing Environments
• NACE SP0188 — Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates
• ISO 4628 series — Paints and Varnishes — Evaluation of Degradation of Coatings — Designation of Quantity and Size of Defects
• ASTM G8 / ASTM G42 — Cathodic Disbondment Testing — undercutting corrosion at coating defects
• SSPC-PA2 — Procedure for Determining Conformance to Dry Coating Thickness Requirements

Key failure modes investigated in coatings include: loss of adhesion from inadequate surface preparation or moisture contamination during application; osmotic blistering from water transmission through the coating film; undercutting corrosion from cathodic disbondment; mechanical damage from impact or abrasion; chemical resistance failure from incompatible service fluids; and delamination of multi-coat systems from intercoat adhesion loss.

Ceramic & Refractory Material Failure Investigation

Ceramic and refractory materials are used in high-temperature process equipment, wear-resistant components, electronic substrates, cutting tools, and structural applications. Ceramics are brittle by nature, and their failure is governed by pre-existing flaws, thermal shock, contact stress concentration, and subcritical crack growth. Refractory linings in furnaces, reactors, and kilns are subject to thermal cycling, chemical attack from process gases and slags, and mechanical spalling. At METS Lab Abu Dhabi, we apply fractographic analysis, SEM/EDS examination, XRD phase identification, and thermal property assessment to characterize ceramic and refractory failures. Our investigation follows:

• ASTM C1322 — Standard Practice for Fractography and Characterization of Fracture Origins in Advanced Ceramics
• ASTM C1161 — Flexural Strength of Advanced Ceramics at Ambient Temperature
• ASTM C1421 — Determination of Fracture Toughness of Advanced Ceramics at Ambient Temperature
• ASTM C704 — Erosion Resistance of Refractory Materials by Abrasive Blast
• ASTM C874 — Rotary Slag Testing of Refractory Materials
• ISO 6872 — Dentistry — Ceramic Materials — for dental ceramic failure investigation
• ASTM C20 — Apparent Porosity, Water Absorption, Apparent Specific Gravity, and Bulk Density of Burned Refractory Brick

Key failure modes in ceramics and refractories include: brittle fracture from impact or thermal shock; subcritical crack growth under sustained stress; chemical corrosion from reactive process gases or molten slags; spalling from thermal gradient stresses in refractory linings; and contact damage from Hertzian stress concentration.

Concrete & Cementitious Material Failure Investigation

Concrete and cementitious materials are fundamental to infrastructure, offshore platforms, marine structures, and industrial foundations. Concrete failures involve a range of mechanisms including carbonation-induced depassivation of reinforcement, chloride-induced corrosion of rebar, alkali-silica reaction (ASR), sulphate attack, freeze-thaw degradation, and mechanical overload cracking. Identifying the governing mechanism and its extent is critical for structural assessment, repair specification, and life extension decisions. At METS Lab Abu Dhabi, we perform petrographic examination, chemical analysis, and physical testing to fully characterize concrete failure. Our methodology follows:

• ASTM C856 — Standard Practice for Petrographic Examination of Hardened Concrete — the primary methodology for concrete failure investigation
• ASTM C642 — Density, Absorption, and Voids in Hardened Concrete
• ASTM C1202 — Electrical Indication of Concrete’s Ability to Resist Chloride Ion Penetration
• ASTM C1260 — Potential Alkali Reactivity of Aggregates (Mortar-Bar Method) — ASR investigation
• BS 1881-124 — Testing Concrete: Methods for Analysis of Hardened Concrete — chloride, sulphate, cement content determination
• ISO 13315 series — Environmental Management for Concrete and Concrete Structures
• ACI 201.2R — Guide to Durable Concrete — ACI framework for concrete degradation mechanism assessment

Key failure modes in concrete include: rebar corrosion from carbonation front advancement or chloride ingress causing cracking and spalling; alkali-silica reaction (ASR) gel expansion causing map cracking; sulphate attack on cement paste; delayed ettringite formation (DEF); freeze-thaw surface scaling; plastic shrinkage cracking; and structural overload cracking.

Advanced Analytical Tools & Instruments Used in Our Investigations

METS Lab Abu Dhabi Abu Dhabi one of the leading failure analysis laboratory in UAE, operates a comprehensive suite of advanced analytical instrumentation for failure investigation of both metallic and non-metallic materials. Our tools enable multi-scale characterization from macro visual examination through to atomic-level elemental and phase identification, providing the complete forensic picture required for defensible root cause conclusions. Key analytical techniques and instruments are listed below:

Microscopy, Fractography & Surface Analysis

Analytical Technique / Instrument	Application in Failure Analysis	Key Standards
Scanning Electron Microscopy (SEM)	Fracture surface fractography, crack morphology, polymer fracture surface features, composite fibre-matrix interfaces	ASM Vol.11 / ASTM E3 / ASTM C1322
Energy Dispersive X-ray Spectroscopy (EDS/EDX)	Elemental analysis of corrosion deposits, coating cross-sections, contamination in polymers and composites	ASTM E1508 / ASM Vol.13A
Optical Light Microscopy (LOM)	Microstructural examination, coating cross-section thickness, composite laminate inspection, concrete petrography	ASTM E3 / ASTM C856 / ASTM E407
Confocal Laser Scanning Microscopy	3D surface topography, wear scar profiling, coating roughness, elastomer surface damage mapping	ISO 25178 / ASTM G40
Stereo Microscopy (Macro)	Macro fracture examination, corrosion mapping, composite delamination documentation	ASM Vol.11 / ASTM D5573

Chemical & Phase Characterization

Analytical Technique / Instrument	Application in Failure Analysis	Key Standards
Fourier Transform Infrared Spectroscopy (FTIR)	Polymer identification, degradation products, coating chemistry, elastomer chemical attack characterization, lubricant analysis	ASTM E1421 / ISO 4650
X-ray Diffraction (XRD)	Phase identification in metals, corrosion products, ceramics, concrete mineral phases (ASR gel, ettringite)	ASTM E915
Optical Emission Spectrometry (OES)	Chemical composition verification of metals and alloys	ASTM E415 / ISO 14284
X-ray Fluorescence (XRF)	Elemental screening of metals, coatings, ceramics, and concrete	ASTM E1085 / ISO 29581
Thermogravimetric Analysis (TGA)	Polymer degradation temperature, filler content, moisture and volatile content in failed polymers and composites	ASTM E1131 / ISO 11358
Differential Scanning Calorimetry (DSC)	Glass transition temperature (Tg), melting point, crystallinity, thermal history of polymers and elastomers	ASTM E1545 / ISO 11357
Inductively Coupled Plasma (ICP-OES/MS)	Trace element analysis, contamination identification in fluids and residues	ASTM D5185

Mechanical & Physical Property Testing

Analytical Technique / Instrument	Application in Failure Analysis	Key Standards
Hardness Testing (Vickers, Rockwell, Brinell, Shore A/D)	Metallic hardness mapping; elastomer and polymer hardness pre/post degradation	ASTM E92 / ASTM D2240 / ISO 6507
Microhardness Testing (HV0.025 – HV1)	Localised hardness profiling at welds, HAZ, decarburized zones, case-hardened layers	ASTM E384 / ISO 6507-1
Tensile Testing (Metals, Polymers, Elastomers)	Residual strength and elongation assessment of failed specimens across material types	ASTM A370 / ASTM D638 / ASTM D412 / ISO 527
Impact Toughness Testing (Charpy, Izod)	Toughness verification and embrittlement assessment in metals and plastics	ASTM E23 / ASTM D256 / ISO 148-1
Adhesion Pull-Off Testing	Coating adhesion before and after environmental or service exposure	ASTM D4541 / ISO 4624
Volume Swell & Mass Change Measurement	Elastomer and polymer chemical absorption quantification	ASTM D471 / NORSOK M-710 / NACE TM0187
Compression Set Testing	Permanent deformation assessment in failed elastomeric seals	ASTM D395 / ISO 815
Metallographic Sectioning & Polishing	Cross-section preparation for microstructural, coating, composite, and concrete petrographic examination	ASTM E3 / ASTM C856 / ASTM E407

Key Failure Modes Investigated — Metallic & Non-Metallic

METS Lab Abu Dhabi investigates the full spectrum of material and component failure modes across both metallic and non-metallic materials encountered in industrial, oil and gas, aerospace, and manufacturing applications. The primary failure modes, their typical root causes, and governing investigation standards are summarized below:

Metallic Material Failure Modes

Failure Mode	Typical Root Causes	Investigation Standards
Brittle Fracture	Low toughness, hydrogen embrittlement, low-temperature service, incorrect material	ASM Vol.11 / ASTM E1820 / BS 7910
Ductile Fracture / Overload	Overload, design understrength, stress concentration, section loss	ASM Vol.11 / ASME BPVC / ASTM E8
Fatigue Cracking	Cyclic loading, stress concentration, surface defects, vibration	ASM Vol.19 / ASTM E647 / BS 7608
Stress Corrosion Cracking (SCC)	Tensile stress + corrosive environment + susceptible alloy	NACE TM0177 / ISO 15156 / ASM Vol.13A
Hydrogen Induced Cracking (HIC)	Atomic hydrogen absorption, susceptible steel, sour service	NACE TM0284 / ISO 15156-2
Sulfide Stress Cracking (SSC)	H₂S environment, high-strength steel, tensile stress	NACE TM0177 / NACE MR0175
Pitting Corrosion	Chlorides, stagnant conditions, passive film breakdown	ASM Vol.13A / ASTM G46 / ISO 8044
Galvanic Corrosion	Dissimilar metal coupling in electrolyte	ASTM G82 / ASM Vol.13A
Microbiologically Influenced Corrosion (MIC)	Bacterial activity (SRB, APB), anaerobic conditions, stagnant zones	NACE TM0194 / ASM Vol.13A
Intergranular Corrosion	Sensitization of stainless steels, grain boundary attack	ASTM A262 / ASM Vol.13A
Decarburization & Embrittlement	Improper heat treatment, hydrogen embrittlement, temper embrittlement	ASTM E1077 / ASM Vol.11
Weld Cracking (Cold / Hot)	Hydrogen cracking, solidification cracking, lack of fusion, lamellar tearing	AWS D1.1 / ISO 6520 / ASME BPVC IX
Creep & High-Temperature Failure	Elevated temperature service, creep void formation, stress rupture	ASTM E139 / ASM Vol.11 / ASME BPVC

Non-Metallic Material Failure Modes

Failure Mode	Typical Root Causes	Investigation Standards
Polymer Brittle Fracture	UV embrittlement, chemical attack, low-temperature service, thermal oxidation	ASM Vol.11B / ASTM D638 / ISO 527
Environmental Stress Cracking (ESC)	Residual stress + incompatible chemical environment in polyethylene, polycarbonate, ABS	ASTM D1693 / ASM Vol.11B
Polymer Creep & Stress Relaxation	Sustained load above creep threshold, elevated temperature, incorrect material selection	ASTM D2990 / ISO 899-1
Thermal Oxidative Degradation	Excessive temperature, oxidative environment, absence of antioxidant stabilizers	TGA / DSC / ASTM E1131 / ISO 11358
Hydrolytic Degradation	Moisture absorption in polyesters, polyamides, and polyurethanes causing chain scission	ASTM D5229 / ISO 62 / ASM Vol.11B
UV & Weathering Degradation	UV radiation, photooxidation, surface chalking, embrittlement	ASTM G154 / ASTM G155 / ISO 4892
Elastomer Explosive Decompression (ED)	Rapid pressure release in gas service causing internal bubble formation and rupture	NORSOK M-710 / ISO 23936-2
Elastomer Extrusion Damage	Excessive clearance gap, high differential pressure, hardness inadequate for service	NORSOK M-710 / ASTM D412
Elastomer Chemical Swell & Softening	Incompatible fluid absorption causing volume swell and strength loss	ASTM D471 / NACE TM0187 / ISO 23936-2
Elastomer Compression Set Failure	Thermal ageing, chemical hardening, loss of elastic recovery reducing sealing force	ASTM D395 / ISO 815
Composite Delamination	Impact damage, interlaminar shear overload, moisture ingress, cyclic fatigue	ASTM D5573 / ISO 15024 / ISO 14130
Fibre-Matrix Debonding	Chemical attack on sizing/finish, thermal cycling, hydrolytic attack on glass fibres	ASTM D3171 / SEM / ASTM D5573
FRP Chemical Permeation & Blistering	Incompatible chemical service, liner failure, osmotic blistering	NACE TM0298 / ASTM D2412
FRP Pipe Fatigue Cracking	Cyclic pressure or mechanical loading exceeding endurance limit of laminate	ASTM D2105 / ASTM D2290
Coating Adhesion Loss / Delamination	Inadequate surface preparation, moisture during application, intercoat contamination	ASTM D4541 / ISO 4624 / NACE TM0185
Coating Osmotic Blistering	Water transmission through film, soluble contaminants beneath coating	ASTM D714 / ISO 4628-2 / ASTM D5229
Coating Undercutting Corrosion	Cathodic disbondment at holidays, chloride ingress, anodic undermining	ASTM G8 / ASTM G42 / NACE SP0188
Ceramic Brittle Fracture / Thermal Shock	Pre-existing flaws, rapid thermal gradient, impact contact damage	ASTM C1322 / ASTM C1161 / ASTM C1421
Refractory Spalling & Chemical Attack	Thermal cycling, slag penetration, alkali attack on silica refractories	ASTM C874 / ASTM C704
Concrete Rebar Corrosion (Carbonation / Chloride)	Carbonation front reaching rebar, chloride ingress from marine or de-icing salt exposure	ASTM C1202 / BS 1881-124 / ACI 201.2R
Alkali-Silica Reaction (ASR) in Concrete	Reactive aggregates + alkali cement + moisture causing expansion and map cracking	ASTM C1260 / ASTM C856 / ISO 13315
Sulphate Attack on Concrete	External sulphate ingress reacting with cement paste causing expansion and cracking	ASTM C1012 / ASTM C856 / ACI 201.2R

Industries We Support

Our failure analysis facility supports a wide range of industries where material integrity, equipment reliability, and documented root cause findings are essential across both metallic and non-metallic materials. We regularly serve the following industries:

• Oil & Gas Exploration, Production & Refining
• Aerospace & Defence
• Automotive & Transportation
• Power Generation (Conventional, Nuclear & Renewables)
• Manufacturing & Heavy Industry
• Electronics & Semiconductor
• Construction & Structural Engineering
• Medical Devices & Life Sciences
• Marine & Offshore Engineering
• Chemical & Petrochemical Processing

What Our Failure Analysis Delivers

A METS Lab Abu Dhabi failure analysis investigation is structured to go beyond identifying what failed — it provides the complete technical evidence package needed to understand why it failed and who is accountable. Every investigation delivers:

• Identification of the True Root Cause of Failure: Not just symptoms — the underlying material, design, manufacturing, or operational factor that initiated failure, whether in metallic or non-metallic components
• Failure Mode Classification: Precise identification of the governing failure mechanism using internationally accepted terminology from ASM Handbook, ASTM, NACE, ISO, and ACI standards
• Improved Product Reliability & Safety: Documented findings that support redesign, re-specification, or requalification of affected metallic and non-metallic components
• Reduction of Downtime & Costs: Prevention of recurrence through evidence-based corrective action that addresses the true root cause rather than symptoms
• Quality Improvement & Regulatory Compliance Support: Structured reports compliant with ASTM E620 and ASM Handbook reporting standards, suitable for quality system submissions, regulatory authorities, and legal proceedings

Why Choose METS Lab Abu Dhabi?

With deep expertise across corrosion science, fracture mechanics, metallurgy, polymer science, composite materials, and structural engineering, METS Lab Abu Dhabi is a leading failure analysis laboratory in UAE for both metallic and non-metallic materials:

• Comprehensive Metallic & Non-Metallic Analytical Capability: We operate SEM/EDS, XRD, FTIR, TGA, DSC, OES, microhardness, tensile testing, and metallographic preparation systems — covering the complete analytical requirements for both metallic and non-metallic failure investigation without outsourcing.
• Internationally Recognized Methodology: All investigations follow established frameworks from ASM Handbook (Vols. 11, 11B, 13, 18, 19), ASTM, NACE, NORSOK, ISO, ASME, AWS, ACI, and BS standards, ensuring findings are technically defensible and universally accepted.
• Forensic-Quality, Legally Defensible Reporting: Our reports are structured to meet the documentation and objectivity requirements of ASTM E620 and industry best practice, suitable for litigation support, insurance claims, and expert witness proceedings.
• Rapid Response for Critical Failures: Our team provides prioritized investigation response for critical field failures in metallic components, sealing systems, FRP pipework, and structural materials requiring urgent root cause determination.

FAQ Section

What is failure analysis and when should I commission it?

Failure analysis is a systematic forensic investigation to determine why a component, equipment item, or structure failed — identifying the failure mode, root cause, and contributing factors across metallic and non-metallic materials. It should be commissioned whenever an unexpected failure occurs with safety, financial, warranty, or legal consequences; when recurring failures are impacting reliability; or when a failure must be documented for insurance, litigation, or quality system purposes.

What types of materials and components can you investigate?

We investigate failures across the full range of engineering materials: carbon steels, alloy steels, stainless steels, nickel alloys, aluminium and titanium alloys, cast irons, engineering polymers (HDPE, PTFE, nylon, PEEK, PVC), elastomers and rubber seals, fibre-reinforced composites and FRP piping, organic and inorganic coatings, ceramics and refractories, and concrete and cementitious structures. Components range from small precision parts and O-ring seals to large structural sections, FRP vessels, and concrete infrastructure elements.

How do you approach non-metallic failure investigations differently from metallic ones?

Non-metallic failure analysis requires specialist techniques and different reference standards compared to metallic investigations. For polymers, FTIR chemical identification, TGA thermal analysis, and DSC glass transition measurement are critical. For elastomers, volume swell, compression set, and hardness change measurements are central. For composites, fibre-matrix interface examination by SEM, laminate cross-section microscopy, and constituent content measurement are key. For concrete, petrographic examination, chloride profiling, and alkali-silica reactivity assessment are the primary tools. METS Lab Abu Dhabi has the full suite of instrumentation and expert knowledge to address all these requirements.

Can your failure analysis reports be used for litigation or insurance claims?

Our reports are prepared to the standards required for forensic engineering proceedings, with complete documentation of evidence chain, analytical data, methodology, and clearly reasoned conclusions. Our experts are available to provide expert witness testimony where required.

How should I preserve and submit a failed component for investigation?

Preservation of the failure evidence is critical for both metallic and non-metallic components. Avoid cleaning, cutting, or handling fracture surfaces. For polymers and elastomers, avoid solvents or aggressive cleaning. Photograph the component in-situ before removal where possible. Package failed components individually to prevent contact damage. Contact our technical team before submitting — we will advise on handling, preservation, and shipping requirements specific to your material type.

How long does a failure analysis investigation take?

Investigation duration depends on material type and complexity. Straightforward single-mode metallic failures can typically be completed within 7–10 working days. Non-metallic investigations involving FTIR, TGA, DSC, or elastomer immersion testing may require 7–14 days. Complex multi-component or litigation-grade investigations may require 2–6 weeks. We provide an estimated timeline at project initiation and communicate progress throughout.   When it fails — in metal, polymer, elastomer, composite, or concrete — we find why, and give you the evidence to act. Share your failure details with us, and we’ll provide a tailored investigation scope and personalized quote.