Thank you.

Whether we connected through a testing project, a tradeshow, or a casual meeting, Stork Herron and Stork MMA Laboratories consider you a friend. As thanks, please accept this free issue of our new quarterly e-newsletter, Storklink, which features news and information about industries we serve and projects that come our way.

Extreme Makeover: Stork helps restore "world's first" electrically welded tugboat  This 90-year old working girl needed much, much more than a facelift.  Read more... Stork hosts annual open house Read more about Cleveland's legendary pig roast (and make sure you're invited to the next one!) New staff, new services: Stork Herron expands Charlotte laboratory  Read more about Stork's newest contacts and capabilities.

LEAD ARTICLES Stork Herron and Stork MMA: Local laboratories with global back-up A message from Charles Noall Chief Operating Officer of Stork Materials Technology. Read more...   Stork in full swing: This season's shows and conferences  Read more about FABTECH, ASNT, and other fall events Why do a failure analysis? 8 reasons you should find out what went wrong. Read more about what a failure analyst can tell you about your product or part.   Stork MMA earns Nadcap approval Read more about Stork MMA's newest quality capability. Stork Manager elected to ASM post                  Read more about Stork Laboratory Manager David Von Rohr. Disabled veterans find new skills and second chances in Stork curriculum  Read more about Stork Herron's work with Quest Career College, offering laboratory technology training to U.S. vets.

Why do a failure analysis? 8 reasons you should find out what went wrong.

Crossing your fingers. Thinking happy thoughts. Wishing really, really hard.

These techniques might do the trick for a low-stakes bingo game, but they're not such good ideas when something goes wrong with your product.

Ignoring the root cause of a failure can have large and broad reaching repercussions. Even an isolated problem has ripple effects.

1. Immediate problem for your customer.
2. Scheduling delay for this and other customers.
3. Supply correction.
4. Production capacity adjustment.
5. Recall situation.
6. Back charges.
7. Reputation damage.
8. And the worst case scenario, litigation.

Failure analysis, conducted quickly and properly, can help keep the ripples in the lower numbers, but how do you know what to look for in a failure analysis?

Stork failure analysts typically investigate a failure in three different ways: fractography, evaluation of the material properties, and assessment of the circumstances of failure and the operating environment. In the majority of cases, using these techniques, Stork scientists can determine the root cause of failure and recommend corrections to prevent future failures.

Fractography is the descriptive treatment of fracture, especially in metals, with specific reference to photographs of the fracture surface. The most common evaluations performed during a full fractographic metallurgical failure analysis include visual examination, scanning electron microscopy, energy dispersive spectroscopy, microanalysis, quantitative chemical analysis, and physical property testing , such as tensile testing and hardness determination.

Visual examinations are performed with both the unaided eye and with magnification provided by stereomicroscopes. These initial observations yield important information regarding the mode of failure and identifying suspect origins. Features such as the location of fracture or cracking relative to geometric features on the component give important information regarding the stress state of the component at the point of cracking. The appearance of the fracture, for example dull and fibrous appearing or reflective and faceted give indications of whether the fracture occurred in a brittle or ductile manner, as does the presence or absence of plastic deformation like necking at the fracture.  Other important features that are looked for during the examination include crack arrest marks, radial marks, and chevron pattern each of which help identify crack origins, the presence of corrosion deposits or oxidation which can indicate at what point in during the component’s process or service life the crack opened, and lastly the presence of mechanical damage or other evidence of outside influences.

Subsequent examination using a Scanning Electron Microscope (SEM) provides high resolution imaging that often reveals fracture features characteristic of the particular failure mode present. Features such as dimples are characteristic of ductile overload, while multiple fine concentric lines or striations are typical of fatigue.  During this phase of the examination the investigator confirms the failure mode and takes a closer look at the suspect initiation areas to identify possible contributing factors, such as inclusions, oxidation, corrosion products, and mechanical damage. 

Semi-quantitative compositional analyses can also be performed at this point using Energy Dispersive X-ray Spectroscopy (EDS). EDS takes advantage of the x-rays generated by the incident electron beam and provides a spectrum of the x-ray energies present.  This resulting spectrum, which resembles a histogram of sorts, reveals the relative amounts of elements present in the area being examined.  Because it is attached to a microscope, this technique allows for the analysis of very small particles, i.e., a grain of sand.  EDS is commonly used to analyze discolorations and stains on fractures, as well as corrosion deposits.

Microanalysis involves sectioning the sample and polishing the resultant specimen to mirror-like finish. Subsequent examination of the specimen is performed in both the as-polished and etched conditions. In the as-polished condition, the Stork scientist is looking for inclusions and discontinuities, such as porosity that might have contributed to cracking. Specimens are also examined for the presence of secondary cracks. Subsequent etching reveals the microstructure of the material which can be compared to the reported thermo-mechanical processing to confirm that the material was processed properly. It also reveals conditions that could contribute to cracking, such as decarburization or alpha case.

Chemical Analysis can confirm that a material is what it was supposed to be or identify an unknown substance; Physical Property Testing confirms or indicates the temper condition of material.

At the culmination of all testing, the investigator takes the data into account with the reported circumstances of failure and documents their findings in a written and photodocumented report. The more information that the investigator has available to them at this point regarding the circumstances of failure, the processing of the part, and history of the part (isolated or recurring problem, normal mode of failure) the easier it will be to pinpoint the root cause of failure. At this point, Stork investigators often begin a new project with the client--developing corrective actions to limit future instances of failure.

Stork's scientific teams include experts in polymers, corrosion, and paint systems. Our engineers come from industry and academia and have wide reaching experiences with multiple material If you're outsourcing for materials, consider outsourcing for testing, to validate the quality and composition of your purchases on the global market.

For more information regarding failure analysis and how it can help you contact Gregory Voss (704) 588 1131 or Dave Kovarik (216) 524 1450.

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Stork Herron and Stork MMA: local laboratories with global back-up

A message from Charles Noall, Chief Operating Officer, Stork Materials Technology

Supporting industry for generations

For more than 175 years, Stork has been adding value to our clients’ engineering and manufacturing processes. Our founders would not recognize many of the materials and technology in our product portfolio today, but we do business in much the same way—focusing on service, innovation and engineering know-how. Today, Stork is a successful public corporation with annual sales in excess of $2 billion, operating globally in the aerospace, engineering services, oil and gas, printing and food processing industries. Materials testing has been a Stork group service for over 100 years, having grown out of Stork’s own in-house testing laboratory in Amsterdam, The Netherlands.

A worldwide network

Stork Materials Technology is one of the largest networks of testing laboratories in the world, with more than 600 scientists, engineers and technicians working in 20 locations in North America and Europe. Supporting clients from the aerospace, oil and gas, power generation, medical and pharmaceutical, construction, machine manufacturing, and other sectors, we offer unequalled capability to test and analyze metallic, composite, and polymeric materials, as well as a wide range of construction materials. Our facilities are equipped with the latest testing equipment and workflow systems, and our clients are able to view their test results securely in real-time, using our StorkView internet portal.

Local roots

From stage sets to tugboats to aerospace components, Stork Materials Technology's three East Coast laboratories cover materials testing needs for a wide swath of industries. Stork Herron in Cleveland, Ohio and Charlotte, North Carolina have been serving the region for almost 100 years with materials and chemical testing history; Stork MMA has over two decades of failure analysis, polymer science and other materials expertise. As with all Stork labs in the U.S. and Europe, Stork Herron and Stork MMA specialize in building customized testing programs—backed up by the national and international resources of Stork Materials Technology—and designed to fulfill clients' internal and external specifications. Whatever (and wherever) you need testing, we look forward to supporting you. Please do not hesitate to call on the experts at Stork.

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Stork MMA achieves Nadcap approval

For more information about Nadcap approval, click here. To learn more about Stork MMA's testing services, contact info.mma@stork.com or call 215-579-7500.

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Stork Laboratory Manager elected to ASM post    

Effective September 2005, Stork MMA Laboratory Manager David Von Rohr will hold the executive position of Secretary in the Liberty Bell Chapter of ASM International (American Society for Metals). He has been an active member of this chapter for many years; his term as Secretary will last 1 year.
 
Von Rohr is a graduate and continuing student at Drexel University. Before joining Stork MMA in 2004, he was Laboratory Manager for the Department of Materials Science and Engineering, specializing in metallurgy, scanning electron microscopy, and optical microscopy, as well as overseeing up to 50 graduate student thesis projects. David’s current responsibilities include managing the Stork MMA metallurgical laboratory, writing standard operating procedures for testing, keeping all procedures up to date, training personnel and ensuring compliance with all auditing bodies. The NADCAP and A2LA recognized metallurgist is also a trained failure analyst, conducting numerous investigations for Stork MMA.

For more information about David Von Rohr or Stork MMA, please contact info.mma@stork.com. To read more about ASM, metallurgical analysis, or failure analysis, click on the links.

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StorkView Landmark: Over 1500 clients receiving critical test results through secure online portal

Stork Materials Technology hit a milestone this summer, as StorkView subscribers in the United States climbed past 1500. In a typical week, Stork clients log on to the web-based portal over 5000 times to monitor jobs status, view test results, and download certifications and reports.

"Our role is to ensure that our clients receive their test data in the shortest time possible," says Mark Jonus, Senior Vice President of Stork Materials Technology. "StorkView greatly reduces time spent waiting for paper certifications and reports to arrive. Our manufacturing clients absolutely rely on the fast results to keep their scheduled production moving. StorkView is simple to administer, very easy to use—and totally secure."

Stork Materials Technology was one of the first nationwide materials testing laboratory networks to successfully implement a LIMS system (Laboratory Information Management Systems) with a fully functional online client portal. Test data is sorted and organized through LabMan software, and the results automatically upload into logs, certifications, and reports, which clients can retrieve from their desktop through the Internet within seconds of a test’s completion.

Since StorkView’s debut, client/users have registered from many different industry sectors, benefiting from these and other features:  

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Disabled veterans find new skills and second chances in Stork curriculum

When a school is working right, everybody gets what they need—the students, the community, and the college itself. When Quest Career College's new Laboratory Technology program is up and running, even the country will benefit.

Quest Career College is a small, accredited Ohio school founded in 1997 to serve adult students by providing coursework and certification in technologies that serve medical, computer, business, and other fields.

"Quest approached us to help develop their new Associate Degree of Applied Science in  Laboratory Technology," says Dave Kovarik, Stork Herron Metallurgical Services Manager. "They're tailoring the degree toward mechanical, chemical, and metallurgical testing, and we're helping them define the curriculum and choose textbooks, and we're also making the laboratory available evenings for student use."

Students will earn a the Lab Technology degree in six quarters of evening classes, twenty hours a week that will take about a year and a half to complete. After approval by the Ohio’s State Board of Career Colleges and Schools, the program will train people with disabilities along with mainstream students.  Quest has a history of working with U.S. veterans with service-connected disabilities including psychological problems such as PTSD (Post-Traumatic Stress Disorder) as well as a variety of physical limitations.

"This is a good opportunity for all of us," adds Dave. "Quest gets new students, the vets get new opportunities to develop skills and careers, and Stork Herron gets acquainted with the next generation of students and potential employees. It's win-win all the way."

For more information about Quest Career College, visit their website  or contact admissions@quest.edu. For more information about Stork Herron, contact info.herron@stork.com.

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^{Left to right: Sue Miller, Gerry Love, Ruth Spibey}

New staff, new services: Stork Herron expands Charlotte laboratory

New equipment in the Nondestructive Testing department and new staff in the office have expanded Stork Herron's testing and inspection capabilities in their Charlotte, North Carolina facility.

A new liquid penetrant line goes into production this fall and is expected to significantly reduce turnaround for Herron clients.

"Liquid Penetrant testing is ideal for a large range of materials, including ferrous and nonferrous metals," says Chief Operating Officer Gregory Voss. "This new line is a major upgrade for our lab and we're working around the clock to get it up and operational. Our clients can expect expedited results on their NDT jobs, with the same degree of quality and service that they're used to."

Three recent hires at Stork Herron in Charlotte bring 2005's grand total to seven new employees. Says Voss, "When we increase our testing capabilities, we have to make sure that our customer service keeps pace. Gerry, Ruth, and Sue reflect our commitment to maintaining high levels of communication and efficiency for our customers. These three—and all of our new staff—have improved our organization in immeasurable ways."

Gerry Love was most recently working in real estate and he holds an MBA, but many of our clients may know him from his background in steel manufacturing and steel servicing. Gerry's impressive track record and body of knowledge led to an offer from Stork Herron in March. Please email or call Gerry to meet him in his current position as a Stork Herron Sales Manager.

Ruth Spibey, as well as her husband John (who's working in the Stork Herron Metallurgy Department), is adapting to the North Carolina lifestyle after many years in Illinois. Clients may recognize her friendly voice; her duties include answering phones, order entry, and other administration support.

Sue Miller will also be an order entry contact for Stork Herron customers, as well as providing certification typing and other customer service assistance. Sue started with Stork Herron in June after eleven years with Weyerhauser; she brings a wealth of office experience.

Please contact info.herron@stork.com for any of your testing or customer service needs.

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