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  • Failure Analysis - Methodology, Techniques and Case Studies

Failure Analysis - Methodology, Techniques and Case Studies

  • 1 Nov 2022
  • 9:30 AM - 12:30 PM
  • Online (Zoom)
  • 395


Registration is closed
Technical Group Webinar


Failure investigation or analysis is an essential activity and skill that is frequently applied to provide an understanding of how and why failures arise in engineering components and structures.

Lessons learnt from failure investigations are crucial for increasing our understanding and can lead for example, to improved design, better material selection, improved fabrication methods and better training of personnel, all of which can reduce the risk of similar failures arising in the future.

Furthermore the process of undertaking a failure investigation can be very stimulating and technically rewarding and it is important that the information and learning is shared within the industry wherever possible.

The meeting will clarify what is meant by a failure investigation and how the scope differs to that of a root cause analysis, a phrase which is commonly mistakenly used to describe the technically focussed scope of a failure investigation. Laboratory equipment and techniques used will be described and several case studies will be presented. Presentations will be given both by TWI Ltd staff and external experts. 

Who should attend?

Relevant to engineers, technicians, project managers, consultants,  metallurgists, materials scientists, students with an interest in failure analysis.

Experts from industry and TWI will be presenting on a range of topics:

  • Joanna Nicholas CEng IWE FWeldI FIMMM, Team Manager - Metallurgy, Materials and Structural Integrity Group, TWI Ltd on Introduction to Failure Analysis and Root Cause Analysis
  • Matthew Haslett CEng MIMechE FWeldI IWE, Team Leader - Environmental Testing, TWI Ltd on Catastrophic Failures - A Case Study
  • Ashfaq Khokhar CEng MWeldI MIMMM, Metallurgy Laboratory Manager, Sandberg LLP on Testing Laboratory Failure Analysis Viewpoint - Equipment and Experience 

  • EUR ING Neil Gallon MA CEng FIMMM, Principal Materials and Welding Engineer, ROSEN Group on Failure Investigation Techniques in Action – Example Case Studies



  • Professional Members of The Welding Institute: £25 + VAT (£30)
  • Industrial Members of TWI: £25 + VAT (£30)
  • Non-members: £95 + VAT (£114)
  • Retired Members: £25 + VAT (£30)
  • Students: £25 + VAT (£30)
  • TWI Training School Customers: £70 + VAT (£84)

TWI Staff - please contact Bethaney Butcher if you wish to register.

Please note that payment must be made before the event in order to receive the joining instructions for the event.


If you can't join us on the day, you can still access the recording of the webinar and the presentations by registering ahead of the event.*

*presentation dissemination is dependent on presenter consent.


Registering on this Technical Group webinar as a non-member or a TWI Training Customer gives you full Associate Membership (AWeldI) for one year. To activate your membership, just complete the highlighted fields on the event registration form.

You will also benefit from:

  • Information transfer from experts
  • Discussion, questions and answers on the specific topics
  • A broader understanding of the extent of standards in the industry
  • Attendance of this event qualifies for CPD 


The Welding Institute awards points towards CPD for delegates attending this webinar. Every hour attendance of an event will earn 2 points towards your continuing professional development.

Please contact if you require a certificate of attendance towards your continuing professional development.


Joanna Nicholas CEng IWE FWeldI FIMMM

Presentation title: Introduction to Failure Analysis and Root Cause Analysis

Joanna joined TWI Ltd in 1999, and has been involved in research, materials selection and failure investigations, mainly with ferritic steels. Joanna has also supported engineering critical assessment activities by undertaking post-test metallographic assessment on fracture toughness test specimens. She has also been involved in various aspects of computer modelling.

Joanna has broad knowledge of ferritic steels with particular emphasis on hydrogen cracking and hydrogen diffusion, HAZ hardness, mooring chain, fasteners, in-service welding and 9% Ni steels. She has carried out numerous investigations in these areas including failure investigation as well as production qualification and research. She currently serves on several BSI committees, providing welding and metallurgy input to the standards as required and lectures on the IIW/EWF diploma.

Matthew Haslett CEng MIMechE FWeldI IWE

Presentation title: Catastrophic Failures - A Case Study

Matthew is Team Leader - Environmental Testing in the Fatigue and Fracture Integrity Management Section, with experience in mechanical and structural engineering. His main areas of expertise lie in fracture toughness testing, mechanical testing, Engineering Critical Assessment (ECA), full-scale testing and bespoke mechanical testing.

Matthew also organises TWI’s training course on Structural Integrity Assessment to BS 7910 and lectures on the Design and Construction module of the EWF/IIW Welding Diploma.

Ashfaq Khokhar CEng MWeldI MIMMM

Presentation title: Testing Laboratory Failure Analysis Viewpoint – Equipment and Experience 

Ashfaq is a Metallurgist and Chartered Engineer with experience in heat treatment, optical microscopy, mechanical testing and failure investigations. Experience on failure investigations includes parent metal (ferrous and non-ferrous) and weld failure from the marine, oil and gas, chemical, automotive, power generation and construction industries.

Ashfaq joined Sandberg LLP in April 2021 after leaving TWI Ltd, where he was a project leader in the Materials department. Ashfaq has gained a wide experience in metallurgy, having worked on arc, friction, laser, electron beam welding projects and failure investigations. 


Presentation title: Failure Investigation Techniques in Action – Example Case Studies

Neil Gallon is a Principal Materials and Welding Engineer with the ROSEN Group in Newcastle upon Tyne, UK. He holds a degree in Materials Science and Metallurgy from the University of Cambridge and is a Eur. Ing., a Chartered Engineer, a Fellow of IoM3 and a European/International Welding Engineer. He has performed, coordinated and assisted in multiple failure investigations over his 25 year career.

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