Metallurgical failure examination in EMHA’s lab or on-site

Metallurgical investigation involves analysing metals and alloys to determine their composition, structure and properties. The aim is to establish the quality, performance and possible causes of damage or wear.

There are various forms of metallurgical investigation, such as:

• Visual and microscopic investigation (including light and electron microscopy)
• Chemical analysis (elemental composition)
• Hardness and strength determinations
• Failure analysis in the event of damage or defects

Why metallurgical damage investigation?

An unexpected break, crack or deformation in a metal component can have major consequences for the safety, reliability and continuity of installations. Metallurgical damage investigation – also known as “Metallurgical Failure Examination” – reveals exactly what went wrong.

Typical questions that are answered include:

• Is there material fatigue?
• Was the correct type of steel or weld metal used?
• Are there any manufacturing defects or stress concentrations?
• What was the influence of corrosion, heat or stress?

At EMHA, metallurgical research is not just about technical analysis, but above all about practical applicability. Results are presented clearly and translated into concrete recommendations, enabling customers to improve processes, prevent damage and substantiate liability.

EMHA B.V. works in sectors such as maritime, energy, mechanical engineering, process industry and offshore, and helps customers with quality control, problem solving and extending the service life of critical components.

Destructive vs. non-destructive testing

There are two main methods of metallurgical testing: destructive and non-destructive testing.

• Non-destructive testing (NDT)

This method leaves the component intact. Techniques such as ultrasonic testing, magnetic testing or X-ray inspection make it possible to detect internal and external defects without damaging the material. The advantage is that the component can still be used afterwards, but the information is often more limited, especially regarding the internal microstructure or chemical composition.

• Destructive testing (DT)

This involves taking a sample from the component or physically machining or cutting the component itself. This enables in-depth analyses, such as metallographic examination, tensile tests, hardness measurements and chemical analysis. Because the material is damaged or destroyed, the component is often no longer usable after the test.

Why EMHA often opts for destructive testing

In many cases, EMHA B.V. opts for destructive testing because this method provides the most complete and reliable picture of the material behaviour, internal structure and actual cause of damage or failure. Especially in failure analyses or quality controls of critical components, it is essential to leave nothing to chance. Destructive testing allows EMHA to determine with a high degree of certainty whether the material meets the required specifications and what the root cause of any problems is.

EMHA’s metallurgical laboratory

In its fully equipped metallurgical laboratory in Hendrik-Ido-Ambacht, EMHA carries out various material tests, including:

• Microscopic examination of material structures
• Hardness measurements (e.g. Brinell, Vickers, Rockwell)
• Chemical analysis via spectrometry or wet chemistry
• Fracture surface analysis (fractography)

In addition to its work in the laboratory, EMHA also offers on-site inspections. This is ideal when dismantling or transporting large, heavy or critical parts is impractical or cost-inefficient. Thanks to mobile measuring and testing equipment, many tests can be carried out directly on site.

Practical examples:

Examples:

1. Inspection of a ship’s propeller in a dry dock

During regular maintenance, damage to the propeller blades was discovered on a cargo ship. EMHA carried out hardness measurements and a visual inspection on site to assess whether material fatigue or cavitation was the cause. This made it possible to determine immediately whether repair or replacement was necessary, thus avoiding unnecessary delays.

2. Damage investigation of turbine blades in a power plant

During a planned shutdown, abnormalities were noticed on turbine blades. EMHA took small samples on site for destructive testing in the laboratory, while hardness measurements and visual inspections were carried out using portable equipment. This allowed most of the installation to remain operational and the cause — thermal fatigue — to be quickly identified.

3. On-site analysis of a weld fracture on an offshore crane arm.

A crane arm on an offshore platform showed cracking in a critical weld. EMHA travelled to the site to analyse the fracture. By assessing the damage on site and taking samples immediately, a repair plan could be drawn up quickly and costly downtime was minimised.

4. Investigation into wear on pump shafts in the process industry.

Excessive wear on pump shafts was detected in a chemical plant. EMHA carried out on-site measurements of hardness, visual inspection of surface condition and material structure. The analysis showed that the wear was caused by incorrect material selection in combination with abrasive particles in the fluid flow. Thanks to the immediate diagnosis, the factory was able to switch to a more durable type of material.

With this approach, EMHA combines the speed and flexibility of on-site research with the depth of laboratory analyses, thereby limiting downtime and providing customers with quick clarity about the cause and solution to material problems.

Steel quality

The quality of steel largely determines the performance of a structure or machine. Poor steel quality or incorrect material selection can lead to premature failure.

Steel is an alloy of iron and carbon, often supplemented with other alloying elements such as chromium, nickel, molybdenum or manganese. The specific composition and heat treatment determine the mechanical properties, corrosion resistance and wear resistance. In metallurgical research, the quality and suitability of the steel is determined by, among other things, chemical analysis, microstructure determination and hardness measurement.

Classification of steel types

Sometimes there is a dispute about the quality or origin of a steel type. In that case, EMHA examines the microstructures of the steel under a microscope. Based on this analysis, a classification can be made: determining exactly which steel type it is, including the associated properties and alloying elements.

This is important because a correct classification:

• Demonstrates whether the material meets the specifications laid down in contracts, standards (e.g. EN, ASTM) or technical drawings.
• Confirms suitability for the application — for example, whether the steel can withstand high loads, wear or corrosive conditions.
• Identifies causes of damage or failure if it turns out that the wrong type of steel has been used.
• Provides support in legal or liability issues, for example in delivery disputes or warranty claims.

In this way, EMHA prevents or settles disputes and helps customers make technically and legally sound decisions.

Steel microstructure

The microstructure of steel is the internal structure of the material, visible under a microscope. This structure consists of different phases and grain shapes, such as ferrite, pearlite, bainite, martensite or austenite. The ratio and shape of these phases are determined by the chemical composition of the steel, the cooling rate after heating and any heat treatments.

The microstructure determines the mechanical and physical properties of the steel, such as:

• Strength and hardness (for example, martensite is very hard, ferrite is softer and tougher)
• Toughness (resistance to fracture)
• Wear resistance
• Corrosion resistance
• Fatigue behaviour (how the material reacts to cyclic loading)

In metallurgical research, EMHA examines the microstructure to determine, among other things:

• Whether heat treatment has been carried out correctly
• Whether stress concentrations or embrittlement have occurred
• Whether welded joints have been carried out correctly
• Whether fatigue cracks are developing

A good understanding of the microstructure makes it possible to predict and optimise the performance of steel and to identify problems at an early stage.

Industrial applications of metallurgical damage investigation

EMHA’s expertise is often called upon in the following sectors:

• Maritime & Offshore
• Oil & Gas
• Civil engineering
• Cranes and heavy-duty machinery

In these sectors, the technical and economic interests are significant. Damage to critical components can lead to prolonged downtime, high repair costs, and in some cases dangerous situations. Metallurgical damage investigation therefore plays a crucial role, because it:

• Ensures safety: Defects in, for example, ship shafts, offshore structures, or hoisting equipment can lead to accidents. Early detection and analysis prevent risks to personnel and the environment.
• Prevents high costs: Timely diagnosis of material problems enables targeted repairs, avoiding expensive replacements or prolonged downtime.
• Substantiates liability: In the event of damage or failure, metallurgical investigation can determine whether the cause lies with the material, design, manufacture, or use, which is essential in legal and insurance proceedings.
• Supports prevention – Analysis of wear or crack patterns provides valuable insights to prevent future damage through, for example, material selection, design modification, or improved maintenance.

Thanks to this approach, EMHA helps customers in demanding industries to keep their installations safe, reliable, and cost-efficient.

Marine & Offshore

Offshore structures are exposed to extreme environmental and mechanical stresses. Saltwater corrosion, cyclic loading, and large temperature fluctuations can all lead to premature material failure. EMHA uses metallurgical damage analysis to determine whether a failure was caused by material fatigue, incorrect steel selection, or manufacturing defects.

Typical offshore applications:

• Analysis of broken bolts
• Investigation of cracked welds
• Inspection of defective mooring components
• Investigation of damaged lifting equipment

The results of this investigation contribute to better material selection, compliance with classification society requirements, and a well-founded root cause analysis after incidents.

Oil & Gas

Installations in the oil and gas sector operate under high pressure, at extreme temperatures, and often in corrosive environments. Material damage can lead to production stoppages, environmental damage, or safety risks. EMHA conducts metallurgical research to determine whether damage is the result of corrosion, hydrogen embrittlement, fatigue, or incorrect heat treatment.

Typical applications:

• Analysis of ruptured high-pressure pipes
• Investigation of crack formation in heat exchangers
• Inspection of valves and flanges for corrosion or wear
• Investigation of broken drill and pump parts

With these analyses, EMHA helps to limit downtime, prevent environmental incidents, and increase the reliability of critical installations.

Civil Engineering

In bridges, locks, cranes, and other civil structures, metal components are often used for many years under heavy loads and varying weather conditions. Damage can have major consequences for safety and infrastructure. EMHA investigates whether material aging, fatigue cracks, or corrosion are the cause of defects.

Typical applications:

• Research into crack formation in bridge structures
• Analysis of bolt connections in locks and weirs
• Inspection of moving parts for wear and metal fatigue
• Inspection of steel cladding and guidance systems

The results form the basis for targeted maintenance and replacement plans and contribute to extending the service life of civil infrastructure.

Cranes & Heavy Duty Machines

Crane and hoisting installations, excavators, and other heavy-duty machines operate under high dynamic loads. Overloading, fatigue, or incorrect material selection can lead to serious damage and downtime. EMHA analyzes fractures, wear, and deformation to determine the actual cause.

Typical applications:

• Investigation of broken lifting hooks or chains
• Analysis of crack formation in boom or frame structures
• Inspection of worn gears and bearings
• Investigation of fractures in hydraulic components

With the results, EMHA helps to minimize downtime, ensure the safety of lifting operations, and extend the service life of machines.

Why choose EMHA for metallurgical analysis?

EMHA – Specialist in metallurgical damage investigation

Customers choose EMHA because of its unique combination of laboratory expertise and mobile deployability. With its own metallurgical laboratory in Hendrik-Ido-Ambacht and the ability to perform on-site analysis, EMHA delivers fast and accurate results.

Our experienced materials scientists have in-depth knowledge of steel and welding research and translate research results into clear, independent reports – suitable for both technical decision-makers and legal processes such as arbitration, damage claims and insurance issues.

Complete damage investigation from A to Z

EMHA takes care of the entire process: from securing samples on site to extensive laboratory analysis and drawing up a clear report with recommendations. We work quickly, carefully and transparently, so that downtime is kept to a minimum.

What does EMHA offer?

• Fast and reliable diagnosis
• Clear reports that are understandable for everyone
• Advice to prevent recurrence
• On-site deployment in the event of acute malfunctions or incidents

Sectors

We work for the maritime industry, offshore, petrochemicals, civil engineering and mechanical engineering.

Typical components under investigation:

Crankshafts, gears, springs, bolts, fasteners, steel and aluminium structures, drive shafts, transmission parts, plate fields, welded structures, bearings, bearing bushes, running wheels and steel cables.

Metallurgical research also provides valuable insights in cases of damage caused by misuse, overloading, incorrect assembly or poor maintenance. EMHA determines whether material defects, fatigue, corrosion, overheating or production errors are the cause, enabling organisations to take targeted measures and prevent future damage.

Interested in metallurgical analysis? Contact EMHA

Are you dealing with material problems, failing components or a dispute about material use? Then metallurgical damage investigation by EMHA is the right step. We offer:

• Quick insight into the causes of damage
• Independent and technically substantiated advice
• Clear reports, also suitable for legal proceedings

Contact us for a no-obligation introduction. View our projects on our website or request a metallurgical analysis directly.