FAI and the Pyro Detective's Toolkit

Abstract

When a failure occurs, failure analysis investigation (FAI) determines what has failed, how the failure occurred, and why it failed. The best answers to these questions are obtained when a systematic approach to failure analysis is applied. Based upon these answers, an analyst can frequently recommend corrective action to preclude recurrence of the failure mode. While the determination of what failed often can be accomplished by simple inspection, systematic approaches, such as Fishbone and Fault Tree Analyses, may be used to study failures in more complex systems. Determining the mode and mechanism of component failure, making use of analytical tools such as SEM/EDS and radiographic inspection, tells the analyst how a system or device failed. Establishing why a failure occurred is of prime importance. Systematic approaches to FAI, such as Kepner-Tregoe (KT) and Root Cause Analysis (RCA) methodologies, applied by multidisciplinary teams, may be used to ascertain the root cause of the failure. An established Failure Recording and Corrective Action System (FRACAS) is essential in providing confidence that the failure will not recur. This paper provides a useful summary of FAI techniques and the important elements of a FRACAS that may be used as a toolkit for the pyro detective. It draws upon examples of pyrotechnic FAIs to illustrate the applicability of analytical tools and approaches.