Failure reproduction
Failure reproduction is a specialised service that allows the mechanisms of failure that may occur in materials, components or industrial systems to be simulated in a controlled manner.
At INFINITIA Industrial Consulting, we approach this service from a scientific and technical perspective, with the aim of validating hypotheses about the causes of failure through accelerated testing.
Thanks to our industrial laboratory, equipped with state-of-the-art technology and a multidisciplinary team with extensive experience in materials analysis, we develop specific tests that reproduce real or extreme service conditions.
This allows us to understand the origin of a failure, evaluate alternative materials and optimise production processes. At INFINITIA, we not only generate valuable technical information, but also provide concrete solutions through a rigorous methodology tailored to each case and the needs of the industrial client.
What does failure reproduction involve?
Failure reproduction consists of designing and executing a set of technical tests that simulate, under controlled conditions, the behaviour that triggers a previously observed failure in a product or component.
This service is key to failure diagnosis processes, as it allows us to verify whether a hypothesis is valid by reproducing the problem under the same parameters of use, stress or degradation, among others.
At INFINITIA, we carry out this reproduction using techniques such as accelerated ageing in climatic chambers, exposure to salt spray, abrasion tests on abrasimeters, thermal tests with climatic chambers, and analysis by chemical resistance or bacterial overgrowth.
Each test is designed according to the type of failure to be studied and can be complemented with characterisation techniques such as FTIR, optical microscopy or SEM-EDS to identify microdamage or alterations in the structure of the material.
This methodological flexibility allows us to adapt the approach to different sectors and types of products.
Key benefits and advantages
The main benefit of fault reproduction is the ability to objectively validate and empirically determine the causes of failure, which reduces diagnostic times and improves decision-making in quality, design or production processes.
In addition, this approach allows industrial customers to evaluate possible material or design alternatives under the same failure conditions, which translates into optimisation of the durability, performance and cost of the final product.
At INFINITIA, we have reproduced failures such as premature oxidation, thermal degradation, friction failures and chemical incompatibility problems, helping our customers to redesign processes, select new materials or modify service conditions to prevent recurrences.
The ability to reproduce the failure also facilitates comparative testing between suppliers or production batches, reinforcing quality control and increasing the reliability of the product on the market.
How we carry out the service at INFINITIA
At INFINITIA, failure reproduction is carried out in our industrial laboratory, combining knowledge of forensic engineering, materials science and functional analysis.
We have specific equipment for performing accelerated testing, climatic chambers, salt spray systems, abrasion equipment, thermal stations and advanced microscopy.
Our process begins with a technical meeting with the customer to define initial hypotheses, after which a test plan is designed that includes simulated service conditions, validation criteria and complementary characterisation techniques.
Based on the results, we propose viable alternatives that can be subjected to comparative tests. All work is documented in accordance with applicable technical standards and can be integrated into root cause analysis (RCA), 8D studies or corrective action plans.
At INFINITIA, we don’t just reproduce the failure, we transform it into applicable knowledge to improve the customer’s processes.
Types of Failure Reproduction Tests
At INFINITIA Industrial Consulting, we develop different failure reproduction tests to evaluate and simulate the failure mechanisms of industrial materials, components and systems.
Our goal is to reproduce failures under controlled conditions and understand their origin in order to optimise the performance, safety and service life of products. Below, we detail the types of tests we perform to simulate failures and how each one contributes to design or process improvement.
Accelerated ageing tests
These tests simulate the wear and degradation of materials and components under extreme temperature and humidity conditions. At INFINITIA, we use climatic chambers and salt spray to accelerate the effects of ageing, reproduce failures such as oxidation or moisture deterioration, and predict the behaviour of materials during their life cycle.
For example, we have used these tests to simulate the degradation of metal coatings on components exposed to adverse conditions, helping to select the best corrosion-resistant material.
Abrasion and wear testing
Abrasion tests simulate the impact and friction that materials are subjected to during use. At INFINITIA, we use abrasion testers to perform wear tests that replicate working conditions such as those that could cause failure in surfaces or moving parts.
These tests are essential in sectors such as the automotive industry, where components must withstand wear and tear from friction and maintain their functional integrity. For example, in an automotive project, we evaluated the wear resistance of plastic components subjected to repetitive friction conditions.
Thermal and overheating tests
Thermal and overheating tests replicate material failure due to temperature variations. We use climatic chambers and thermal stations to expose materials to rapid temperature changes, simulating thermal failures such as polymer degradation or thermal fatigue in metals.
At INFINITIA, we have tested electronic and electrical materials to simulate and reproduce thermal failure and improve the durability of electronic components under extreme temperature conditions.
Chemical resistance tests
These tests simulate the behaviour of materials when exposed to chemical aggressions that can cause failure, such as oxidation, corrosion or degradation by chemicals. At INFINITIA, we perform analyses using FTIR, optical microscopy and SEM-EDS to study the chemical resistance of materials to various reagents.
A recent case involved the simulation of failures in plastic coatings exposed to aggressive chemicals, helping to improve the chemical resistance of materials used in the automotive industry.
Bacterial overgrowth tests
In some sectors, failures due to bacterial overgrowth can compromise the functionality of a product. This type of test is key in the validation of materials for medical, pharmaceutical or food applications. At INFINITIA, we use microbiological techniques to reproduce failure due to bacterial growth on surfaces or materials in contact with pathogenic organisms.
An example of this is the simulation of failure in materials where we analyse resistance to bacterial growth and thus prevent potential failures in real conditions.
Applications of failure reproduction
Failure reproduction has fundamental applications in many industrial sectors. Through accelerated testing, failure simulation and comparative analysis, at INFINITIA we help to validate products, select materials and anticipate possible failures in real-life conditions. Below are some of the sectors where this service is key.
Automotive industry
In the automotive industry, materials must withstand vibrations, mechanical loads and extreme weather conditions. Failure reproduction allows us to simulate thermal or corrosion failures in critical parts such as plastic housings or metal coatings.
At INFINITIA, we carry out accelerated tests to evaluate the resistance of materials to extreme conditions, such as accelerated ageing or exposure to salt spray, and improve their performance in automotive applications.
- To validate some plastic casings that had failed, thermal cycles and mechanical analyses were carried out to reproduce the failure and ensure their integrity in prolonged use.
- To validate some metal coatings, salt spray tests were carried out, and the results were compared to select the most corrosion resistant option.
- To check the mechanical strength of structural parts, tensile and cyclic bending tests were carried out to ensure their durability.
Electronics industry
In the electronics sector, materials must offer thermal stability and dielectric strength. Failure reproduction allows faults due to thermal overload or electrical fatigue to be simulated in key components such as encapsulations and insulators.
INFINITIA performs thermal and overheating tests to validate materials used in electronic circuits and batteries.
- To validate the insulation capacity of dielectric materials, dielectric breakdown tests were carried out to predict the breakdown voltage of a material and select the appropriate insulators.
- To validate the thermal resistance of electronic circuit cables, a study of their behaviour at different temperatures was carried out using DSC and TGA.
Construction industry
Construction materials must maintain their structural integrity in the face of moisture, loads, abrasion and chemical agents. Failure reproduction allows us to anticipate their long-term behaviour and validate solutions in accordance with technical standards.
At INFINITIA, we carry out accelerated tests on facade panels and industrial flooring to assess their resistance to environmental conditions.
- Compression tests were carried out on reinforced concrete to simulate working conditions and ensure its integrity up to maximum values.
- Accelerated ageing tests were carried out on facade panels to assess their response to moisture and UV radiation.
- To validate industrial flooring, surface wear tests were carried out using mechanical tests.
Energy
In the energy sector, materials must offer thermal stability and dielectric resistance to load cycles and extreme conditions.
INFINITIA performs thermal and chemical resistance tests to validate components for solar panels, batteries and energy systems.
- The chemical attack on electronic components was simulated to validate their stability and wear under controlled conditions.
- To validate the thermal resistance of electronic components, temperature cycles were carried out to select the most resistant option.
- To validate the quality of materials under environmental and demanding conditions, salt spray tests were carried out to reproduce failure and ensure corrosion resistance.
Medical devices
Medical materials must withstand sterilisation processes and maintain their dimensional stability.
At INFINITIA, we perform thermal and sterilisation resistance tests to guarantee the safety and functionality of materials used in implants, coatings and disposable devices.
- To validate the stability of polymers, salt spray tests were performed to reproduce failure and ensure integrity.
- To validate the compatibility of materials with the sterilisation process in which they were involved, a temperature and humidity ageing test was carried out.
Failure Reproduction with INFINITIA
At INFINITIA Industrial Consulting, failure reproduction is a fundamental service for thoroughly understanding the failures that can occur in industrial materials, components and systems. Through accelerated testing, failure simulations and comparative analyses, we help our clients identify the root causes of problems and validate hypotheses on how to prevent future failures. This approach not only allows us to optimise product design, but also to improve the durability, reliability and safety of the materials used in the most demanding sectors.
Our experience in forensic engineering allows us to go beyond superficial diagnosis. At INFINITIA, we carry out customised tests based on the specific conditions of each client and product, adapting the simulation methods to the particular needs of each industry. Whether through accelerated ageing, thermal testing, abrasion testing or chemical failure simulations, our goal is to provide solutions that minimise risk and maximise the reliability of end products.
In a world where innovation and quality are critical to success, having a strategic partner like INFINITIA in failure reproduction can make all the difference. The benefits of performing these tests include better resource management, material optimisation and, most importantly, the prevention of failures that could affect the safety, functionality and reputation of products. Future trends point towards an increase in the customisation of tests, greater integration of digital technologies to monitor and model failures, and process optimisation.
With INFINITIA, companies can be confident that their products will undergo rigorous testing to ensure performance and quality. In addition, we can offer proactive solutions to improve your processes and ensure long-term competitiveness.
We work closely with our customers to identify problems, simulate failures and offer alternatives for improvement that not only help solve problems, but also optimise their production lines and quality processes.