COMMON FAILURE MECHANISMS IN NON-METALLIC MATERIALS

As non-metallic fabrication materials such

as polymers, ceramics, fiber-reinforced composites, and coatings
continue to see increased usage in manufacturing applications
where metallic materials are too heavy or too susceptible to
corrosion, it’s important that stakeholders ranging from design
engineers to procurement professionals understand the various
problems and limitations that can arise if materials are not
carefully selected. This understanding can be achieved through
comprehensive failure analysis testing.

Failure analysis testing requires extensive expertise and

knowledge across a wide range of materials and failure modes.
Analyzing fatigue characteristics of materials in advance can give
engineers an advantage before they ever begin prototyping and
testing their designs, while post-failure testing can help designers
correct design flaws or inadequate material choices.

COMMON NON-METALLIC FAILURE MODES

There are a multitude of modes that can cause failure of non-

metallic materials, each with its own array of potential causes. It
should be noted that there is often overlap between modes, and
that similar failure modes can sometimes occur in metallic
material as well, though the ultimate effect on non-metallic
material may present differently. Some of the most common
modes discovered in non-metallic failure testing include:

1. Fracturing

A common failure mechanism in polymers, composites, and

ceramics, fracturing often occurs cyclically and may not be
noticeable until an object or material experiences failure. In many
cases, fractures occur over time due to constant or cyclical stress
on the object in question. This happens most often when an
improper material that can’t handle necessary weights or stresses
is chosen for an application, or when a design flaw focuses undue
stress on one particular area of a component.

Example: A ceramic engine part becomes brittle after heat from

engine operation causes thermal expansion. The weakened part
then fractures during normal operation.

2. Fluid Aging

Fluid aging is sometimes referred to as “corrosion for polymers,”

and encompasses more common terms such as hydrolysis, acid
hydrolysis, or alkaline hydrolysis. The term refers to chemical
interactions between certain polymers and water or other
chemicals that may compromise the integrity of the original
material. This process occurs over time, and as such may not be
noticeable prior to failure.

Example: Fluid aging compromises the integrity of the internal

wall of a plastic pipe over a period of time, but isn’t noticeable
until the reaction causes a leak.

3. Thermal Aging

Non-metallic materials used in applications where they are

exposed to high temperatures can experience eventual
degradation, so it’s crucial for design engineers to select
materials that have thermal tolerances appropriate to the
intended application.

Example: A non-metallic protective coating melts or erodes under

prolonged heat exposure, leaving the substrate exposed and
susceptible to damage.

4. Fatigue

Fatigue and failure are often used interchangeably, but doing so

isn’t a correct use of the terms. Fatigue is simply one failure
mechanism, in which prolonged cyclical stresses cause undue or
unexpected wear on a part until it ultimately fails.

Example: In composites, repeated support of extreme weights can

cause fibers to tear. Similarly, in polymers, prolonged or cyclical
exposure to weight or pressure can cause cracks that eventually
lead to failure.

5. Creep

Creep is similar to fatigue. However, instead of cracks or tears,

the part becomes slowly deformed over the course of repeated
exposure to stress or extreme temperatures.

Example: In fiber-reinforced composites, threads may not break

under stress, but instead potentially stretch or bend due to
cyclical increases in load exposure, which reduces the
effectiveness of the overall part.

6. Delamination

This mechanism occurs when cyclical stresses or direct impact

damages the bond between layers or fibers in composite
materials. Fiber-reinforced composites rely on accurate layering
for their strength, so delamination can severely compromise the
material’s mechanical strength.

Example: A fiber-reinforced composite boat hull impacts an

unexpected object at a high speed. While the damage may not be
obvious, the integrity of the hull becomes compromised as the
fibers break and the layers separate.

7. Material Selection/Composition

While not a failure mechanism itself, per say, material selection is

crucial to the prevention of premature component failure.
Improper material selection can result in any of the above failure
mechanisms (which depends on the material). Failing to select the
correct material with the appropriate molecular composition for
the application can result in a range of problems, from shortened
service life to unexpected critical failure.