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Conducting a materials failure analysis requires a carefully planned series of steps intended toarrive at the cause of the problem. Consistent with the current trend towards better accountabilityand responsibility, failure analysis purpose has been extended in deciding which party may beliable for losses, be they loss of production, property damage, injury, or fatality [1]. Hence itincreases the importance of proper implementation of characterization tools in failure analysis torightly identify the failure mode.Present work discusses a few case studies to shed light upon the importance of the metallurgicalcharacterization tools and techniques in identification of correct failure mode. Some typical casestudies where metallography plays a very important role have been discussed, such as improperwelding joints which led to premature failure, sensitization and stress corrosion cracking in S.S.,improper heat treatment and forging indicated the microstructures which led to the prematurefailure. These cases are examples of only a few laboratory based investigations which justify thatwithout metallography it is not possible to diagnose the causes of premature failures.Generally, examination of failed components commence with the low-power stereomicroscopewhereas hand-held magnifying lenses are still in wide use by experts to study fractures mostlylimited now for field purpose [2]. Metallographic examination typically is performed after nondestructiveand macroscopic examination procedures while using the light optical microscopywhich helps to assess the failure mode with respect to material defects, shortcomings inprocessing, metallurgical changes etc. Since light optical microscopy has limited value for directobservation of fracture surfaces (more limited for metals than non-metals), with still more factualinformation can be gathered by scanning electron microscopy at higher magnification.
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