Mechanical Component Failure Analysis and Redesign

In one customer situation, Applied Ultrasonics’ engineers quickly identified that a high-cycle component failed at a geometric stress riser. It is common assumption that fatigue failure is isolated to weldments, but the component had been failing in base metal at a stress riser caused by design geometry.

The customer accepted a solution proposed by Applied Ultrasonics’ engineering staff to change geometry and manufacturing process – resulting in a viable solution that improved mechanical component life, while also decreasing manufacturing cost. Applied Ultrasonics’ engineering solution was fairly simple, but the solution required a deep understanding of the customer’s complex life-cycle issues.