Chapter 2—The Physics of Failure—download from the Industrial and Manufacturing Wellness Book Explaining the PWWEAM Methodology
Using the Physics of Failure is how to get exceptional reliability. PoF is the science that explains the causes of parts' microstructure failure so you can stop them and create outstanding reliability
Use the Science of Parts Failure to Get Outstanding Equipment Reliability
Physics of Failure (PoF) analysis identifies the physical, chemical, mechanical, thermal, biological, and electrical causes that can degrade or deform components to failure. The simple PoF analysis used in PWWEAM methodology identifies possible failure root causes in a part’s environment. You then proactively select effective mitigations across the part’s life cycle to eliminate or control those root causes. And so you create outstanding equipment reliability.
With this post, paid subscribers can download Chapter 2 of the Industrial and Manufacturing Wellness Book (extended version): Physics of Failure. Everyone else and free subscribers have the following Chapter 2 summary.
Summary of Chapter 2: Physics of Failure (ChatGPT generated)
Chapter 2 of the Industrial and Manufacturing Wellness (extended edition), The Physics of Failure, lays out the fundamental mechanisms by which machine parts degrade and fail, and how understanding these processes underpins reliable equipment design and maintenance.
Overload vs. Fatigue
Machine parts fail when applied stresses exceed their microstructural strength. Sudden, excessive loads cause overload—atomic bonds separate and material breaks. Repeated, fluctuating stresses induce fatigue, gradually weakening the microstructure until a critical load triggers failure .Strategic De-rating
A case study comparing identical diesel engines in maritime and rail service illustrates that operating at 90 % of nameplate capacity can cut maintenance costs by two-thirds. Running at full design load accelerates wear, while modest de-rating extends part life dramatically .Probabilistic Nature of Material Strength
Both material strength and operational stresses follow probabilistic distributions. Reliability is maintained by ensuring the highest operating stress remains well below the weakest material’s capacity—a “factor of safety” gap. Exceeding this gap (through overload or degradation) lets weak parts fail first, but strong parts will follow under continued stress .Physics of Failure (POF) Methodology
POF applies computer modeling and accelerated testing to characterize how materials behave under mechanical, thermal, and environmental loads. By defining the design envelope and monitoring operating stresses, engineers can prevent conditions that lead to breakdowns .Reliability Cliffs
Small deviations in contamination level, bearing clearance, shaft alignment, or loading can precipitate precipitous drops in service life—so-called “reliability cliffs.” For example, hydraulic particulate contamination above ISO 18/15 sharply reduces machine life, and a 2 µm error in bearing preload can cost 10 % of service life .Degradation Cycle and Maintenance Strategy
Parts progress from “potential failure” (P) to “functional failure” (F) along a degradation curve. The Physics of Failure tells us that the degradation curve results from microstructure failure. The standard maintenance strategy is regular inspection and condition monitoring (from simple observation to sophisticated sensors) to conduct interventions before F, forming the basis of predictive maintenance (PdM). This strategy requires parts microstructure to fail and generate a signal for detection. PWWEAM strategy is to use Physics of Failure science to prevent microstructure failure and ensure exceptional parts reliability.
In sum, Chapter 2 emphasizes that reliable plant operation demands designing for ample safety margins, controlling operating stresses, preventing environmental degradation, and applying POF insights to monitor and mitigate microstructure failure risks.
Put the Knowledge in Chapter 2 to Effective Use
The Physics of Failure analysis in PWWEAM is used to prevent the causes of component microstructure failure. It identifies how to create and protect a part’s health and wellness throughout its life. It generates proactive design, manufacture, operating, and maintenance strategies and actions to use in its life cycle to ensure a component’s environment, condition, and integrity deliver outstanding reliability its entire operating service life.
Once you read the chapter, let me know if you have any questions.
All the very best to you,
Mike Sondalini
P.S. The chapter download is available behind the paywall below. Become a paid subscriber for USD $5 per month or USD $50 per year, and download complete chapters in the extended version of the Industrial and Manufacturing Wellness book. All 26 chapters, including the worked examples, will be made available two chapters per week to paid subscribers only.