Applications of thin-film replica on failure analysis

This paper is to study the use of thin-film replica technique with an aim to build up a nondestructive inspection method for failure analysis. By the use of this technique, the specimen surface can be reproduced perfectly on a replicated thin-film without any destroying of the specimen. Characteristics such as surface morphology, microcracks and defects on surface can be reproduced truthfully on which they were analyzed. Failure can then be prevented in advance. The technique is shown and demonstrated by analyzing two practical failure cases: A) abrasive wear; & B) defect in cast aluminum piston. The procedures such as preparation and processing as well as application were studied. The effect was discussed in comparison with traditional destructive method. It has advantages of nondestructiveness in addition to the easy preparation and excellent replication of specimen surface in revealing morphology and microcracks. Besides, it can also be used as extractive replica that extracts particles out of the matrix and thus allows a direct observation and analysis without the interference from matrix. Its application in micro elemental analysis and identification is unique. For comparison, the traditional metallographic method was also employed and discussed.