Heat Exchangers Failure Analysis

Metallurgical Heat Exchanger Failure Analysis – Forensic Engineering

Process line heat exchanger failures can be very costly or even catastrophic for a business. Metallurgical heat exchanger failure analysis along with metal corrosion testing and investigation services provided by Metallurgical Technologies, Inc. can help minimize and eliminate the undesirable aspects of unexpected down time. When the root cause of the metallurgical/corrosion failure is identified, results are quickly communicated and recommendations made to help prevent future events.

MTi has significant experience in the failure analysis of commercial and industrial plate heat exchangers, shell and tube heat exchangers, radiators and coolers. We offer rapid turn-around on all heat exchanger tube failure analyses, which includes deposit analyses, or microbiologically induced corrosion (MIC) testing if suspected.

We have analyzed and determined the cause of corrosion, stress corrosion cracking, solder problems and fatigue cracking in plate heat exchangers.

We have also analyzed and worked out solutions with our clients on a multitude of issues in shell and tube heat exchangers including: Tube roll expansions in tubesheets resulting in fatigue failure (due to stress raisers introduced by faulty mechanical roll expander), Stress corrosion cracking at over-roll locations at tubesheet intersections, Crevice and wastage corrosion in open tubesheet crevices, Stress corrosion cracking in U-bends and hot end baffle intersections, Wear at baffle supports, Corrosion due to acid cleaning issues, Intergranular corrosion at baffle intersections, Under deposit and oxygen pitting, Chloride pitting and stress corrosion cracking, Thermal fatigue due to welding and dissimilar issues, Microbiologically induced corrosion (MIC), Flow induced vibrational fatigue and erosion, and other various problems encountered.

Please see some of our case histories for examples of our heat exchanger projects below.

Also see our section specific to the Power and Utility Industries for examples of boiler tube failures.

The information presented is copyrighted and may not be downloaded, reused, modified, distributed, or otherwise used without the express written permission of Metallurgical Technologies, Inc. P.A.


Heat Exchanger Failure Analysis Case Studies:

Preheater Tube Failure Case Study


Metallurgical failure analysis of a component can prevent recurring failures, help with preventative detection, or suggest remedies. If you have a metal product failure that you would like investigated, just take a moment to fill in our information request form and we’ll gladly provide you with an estimate.


Failure Analysis Services

Determine cause of failure & recommend ways to prevent future recurrence.

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Corrosion Investigation

Determine cause of material degradation that reduces life expectancy.

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Verify fracture mechanism & initiation. Microstructure composition and imaging.

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Metallography Services

Reveals grain structure, thermo mechanical processing & flaw and defect characteristics.

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