Alloy Material Testing

Services Provided

The following tests were performed:

• ICP-OES chemical composition analysis
• Oxygen, nitrogen, and hydrogen (O-N-H) content analysis
• Optical microscopy + SEM metallographic analysis
• Vickers hardness testing

Findings

• Oxygen content was 0.22%, exceeding the Ti-6Al-4V standard limit of 0.20%.
• Local α-phase segregation was observed.
• Average hardness was HV 378, higher than the standard range (HV 349–368).

Conclusion and Client Benefits

The elevated oxygen content increased material hardness and reduced machinability, causing excessive tool wear. The client adjusted their procurement standards and changed suppliers, avoiding potential batch quality issues and reducing subsequent processing losses and downtime.

Client Feedback

"Alfa Chemistry’s report was very detailed. It not only identified the problem but also explained how the elevated oxygen content affected machinability, allowing us to quickly pinpoint the root cause. After changing the material, the tool wear issue was immediately resolved, significantly improving our machining efficiency."

— M.S., Materials Engineer, Aerospace Component Manufacturer

Services Provided

The following analyses were performed:

• XRF + ICP-MS chemical element analysis
• Salt spray testing (ASTM B117)
• SEM + EDS analysis of corrosion products
• Metallographic analysis, including Secondary Dendrite Arm Spacing (SDAS) measurement

Findings

• Iron content was 0.74%, exceeding the standard limit of 0.60%.
• Large amounts of β-Al₅FeSi intermetallic compounds were present, serving as corrosion initiation sites.
• Salt spray tests showed dense corrosion spots, and EDS revealed clear Fe and Cl enrichment zones.

Conclusion and Client Benefits

The excessive iron content caused microstructural defects, accelerating material failure in corrosive environments. The client used the report to claim against the supplier and optimized die-casting temperature control and material acceptance criteria. Subsequent batches passed corrosion testing successfully.

Client Feedback

"We had previously conducted multiple inspections but could not identify the root cause of early corrosion. Alfa Chemistry’s analysis helped us pinpoint the problem at the microstructural level for the first time. The report was clear, evidence-based, and extremely valuable for supply chain management."

— J.T., Materials Quality Supervisor, Automotive Manufacturer

Services Provided

The following tests were conducted on the failed gears:

• SEM fracture analysis
• Carbon and sulfur (C/S) content analysis
• Hardness distribution testing
• Metallographic analysis, including carburized layer depth evaluation
• EDS inclusion analysis

Findings

• SEM revealed typical fatigue initiation zones with characteristic fatigue striations.
• Carburized layer depth was only 0.6 mm, below the standard requirement of ≥0.9 mm.
• Sulfur content was 0.035%, significantly exceeding the client’s requirement of ≤0.015%.
• Numerous MnS inclusions were observed, reducing fatigue strength.

Conclusion and Client Benefits

The failure was caused by both insufficient carburized layer depth and elevated sulfur content. Based on the report, the client changed suppliers and strengthened carburizing process control. No similar gear failures occurred in the following year, greatly reducing downtime losses.

Client Feedback

"Alfa Chemistry’s failure analysis report was highly professional and helped us completely resolve a problem that had troubled us for months. They not only identified the material defects but also provided actionable improvement recommendations, which greatly assisted our subsequent process optimization."

— R.W., Project Manager, Mining Equipment Manufacturer