Damage analysis laboratory: Damage analyses according to VDI 3822

The first step in damage analysis is to describe the damage. The aim is to document the damage pattern, i.e. the appearance, shape and location of the damage. Important structural features and material characteristics should also be recorded. The documentation can be done using photos or a verbal description.

After the damage description has been completed, the situation surrounding the damage is examined in more detail in the inventory. In addition to general data, such as the manufacturer and age of the defective product, the main focus is on recording environmental influences that may have caused or contributed to the damage (damage history). These may also be special events that may have occurred before a component failed. The function of the component is also described in the context of the description of the overall system. Data on any damage that may occur frequently is also important.

With the help of the information collected so far and the experience of the investigation team, an initial damage hypothesis can now be formulated. To do this, a probable, hypothetical cause of damage is established from the macroscopically visible damage pattern and the available data, which is to be proven by the subsequent investigations.

Based on the damage hypothesis, an investigation plan is drawn up that can be used to prove the hypothesis. Investigations are also carried out that can reliably refute the hypothesis. All destructive and non-destructive methods of material testing are used as investigation methods. It is important to plan the sampling precisely so as not to destroy evidence or prevent investigations from being carried out. Simulating or re-enacting the suspected damage sequence in tests is often helpful.

The results of the analysis are then used to compare them with the damage hypothesis. If the investigations show clear evidence that supports the hypothesis, the cause of the damage can now be determined with a good degree of probability. However, it is often also necessary to revise the damage hypothesis based on the findings and to substantiate it with new investigations.

If the damage hypothesis is considered confirmed, the cause of the damage is considered to have been found. It is documented, broken down into primary and secondary damage factors. Based on the cause of the damage, measures are then taken to prevent further damage or immediately necessary precautions (e.g. recall campaigns).

The damage analysis is finally documented in a report that contains all the important information from the previous sub-steps. Appropriate measures (knowledge management) are also used to ensure accessibility and storage for future use.

failure, malfunction, breakage, etc.