Failure analysis methodology is applied to the principal mechanisms by which plastics fail during service.
Several important factors often associated with component failures are deficiency in design, fabrication,
unsuitable service conditions, materials selection, and expended useful life. These factors are of primary
consideration. The failure analysis procedure, or methodology for evaluation, is provided in a step by step
approach. This includes justification for conducting a failure analysis investigation, developing a logical plan for
the investigation to follow, collection of background information, the on-site inspection, sample removal
techniques, laboratory testing and analysis, engineering calculations and the formulation of final report based on
relevant data, analysis, and recommendations. Three substantive case studies are presented to illustrate the
methodology: natural gas regulator plastic stem guide, polyester fiberglass insulators, and fiberglass rod and
connector.
Keywords: failure analysis, plastics, polymer composites, natural gas regulator stem guide, insulator, rod and
connector, case studies.