Failure Analysis Services
REQUEST A QUOTEPinpoint Failures Fast to Minimize Downtime
When components fail, speed is critical. Constellation PowerLabs uses advanced techniques including material, chemical, dimensional and other forms of testing, to rapidly identify the failure, so your team can respond with confidence and take the right corrective actions.
If you need fast, accurate failure analysis services, contact us to get the answers you need.
Over 50+ Years of Identifying Defects & Delivering Precision
Since 1964, Constellation PowerLabs has helped engineering teams across the US and Canada identify the root cause of failures and take the right corrective actions with confidence.
Through our failure analysis services, we support critical industries such as nuclear, aerospace, and manufacturing, helping maintain safety and keep production moving.
Detailed Reports
Our failure analysis services reports reveal what failed, how it failed, and what the evidence shows, so you can take preventive action in future.
Built-In Lab Expertise
With material, chemical, and other forms of mechanical testing services in-house, we are equipped to handle complex analyses with accuracy.
Fact-Based Failure Confirmation
We identify whether a part met the original specs, was built incorrectly, or failed in service, backed by lab results.
Trusted Input for Your Next Step
Our analysis supports supplier discussions, quality reviews, and design evaluations with third-party credibility.
Decades of Data to Inform Fast Insight
Through our PQI testing, we often recognize failure patterns early, helping you act faster.
Our 360° Failure Analysis Services
At Constellation PowerLabs, we offer full-spectrum failure analysis services through advanced material and dimensional testing, all performed in-house at our U.S.-based mechanical testing laboratory. Our engineers help identify contamination, verify whether parts meet specifications, and determine if they were improperly manufactured, incorrectly installed, affected by maintenance issues, or failed in service.
Material Analysis
- SEM (Scanning Electron Microscopy): Uses electron scanning to magnify surfaces from 10x to 200,000x with a resolution of 5.0 nm at 30 kV, revealing fracture features, microstructures, and material composition to support failure analysis.
EDS/EDX (Energy Dispersive X-ray Spectroscopy): Detects elemental composition in base materials, welds, or contaminants. - OES (Optical Emission Spectroscopy): This type of failure analysis service confirms if metals meet specifications or contain unexpected alloying elements.
- FTIR (Fourier Transform Infrared Spectroscopy): Identifies polymers, oils, and other organics by matching spectra to an 11,000-compound database.
Wilson Rockwell Hardness Testing Series 500 & Series 2000: Measures material hardness to verify heat treatments and grade specifications.
Dimensional Analysis
- 3D Laser Scanning (Creaform HandySCAN): Non-contact, high-resolution 3D measurement for wear, deformation, and dimensional analysis with accuracy up to 0.025 mm and volumetric accuracy of 0.020 mm + 0.040 mm/m.
- Keyence Optical Comparator: Uses shadow projection for fast, non-contact dimensional inspection to detect profile deviations and surface wear, backed by our A2LA accredited calibration expertise.
- Keyence VHX Digital Microscope: Captures high-resolution images with advanced 2D measurement and particle analysis capabilities.
- Keyence XM Handheld Probe CMM: Portable 3D measurement of GD&T features with ±8 µm accuracy.
Traditional CMM: High-accuracy, contact-based dimensional inspection for complex parts and tight tolerances.
Performing Failure Analyses on High-Stake Components With Accuracy
At Constellation PowerLabs, we specialize in analyzing failures in high-risk, high-impact components, where accuracy drives critical decisions and downtime is not an option. From industrial applications to testing of primary electrical components for nuclear facilities, we provide the data needed to evaluate performance, investigate issues, and proceed further.
We regularly perform failure analysis services on a wide range of mechanical, electrical, and electromechanical components. Our offerings also support programs like counterfeit parts prevention, where detecting off-spec or non-authentic parts is critical.
| Structural and Mechanical Testing | Electronic and Electrical Component Testing | Electromechanical and Rotating Equipment | Insulation and Interfaces |
|---|---|---|---|
| Bearings | Circuit boards | Pumps (gear, hydraulic) | Cables |
| Pipes | Diodes | Diesel engines | Insulators |
| Gaskets | Switches | Solenoids | Connectors |
| Welds | Relays | Transducers | |
| Valves | Voltage regulators | Pressure switches | |
| Bolts | Power supplies | ||
| Transformers |
Our Failure Analysis Process
When a component fails, timely and accurate analysis is critical to avoid further disruption. Our failure analysis services follow a structured process designed to provide clarity at every stage. Upon arrival, our technical engineers evaluate your part. We focus our outcomes on giving your team the insight needed to take informed, corrective action.
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Send Us the Equipment
Ship your part to any of our laboratory locations in the USA. We will transfer it internally to the appropriate testing lab.
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Perform Failure Analysis Testing
Based on the nature of the failure, our technicians perform a range of tests, including material, chemical, mechanical, or dimensional analysis, to gather the data needed for accurate evaluation.
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Receive a Detailed Report
Our testing and calibration lab provides you with an exhaustive report that includes test data, annotated images, and clearly stated conclusions. When applicable, we provide observations to support potential corrective actions or process improvements.
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OneLab Portal
To keep you involved in our failure analysis services process, our OneLab portal allows you to track progress, access documentation, and manage submissions with transparency and convenience.
Internationally-Recognized Accreditation Standards
Our services span far beyond failure analysis. Constellation PowerLabs provides a full range of 17025 accredited calibration and testing capabilities, including high-voltage testing, dimensional inspection, and electrical calibration, backed by A2LA accreditation. We operate in compliance with the following standards and requirements:
- ISO 17025 accredited under A2LA
- Appendix B calibrations
- Routinely audited by NUPIC and NIAC, which satisfies the requirements of 10 CFR 50, Appendix B and 10 CFR 21.
Protect Your Operations with Failure Analysis Services in the USA & Beyond
When a failure takes place, the right response keeps it from happening again. Our failure analysis services give you the evidence to take the right next steps, whether that means replacing a part, changing suppliers, or validating components before they go into service.
Constellation PowerLabs is a leading mechanical and electrical testing company with decades of expertise in testing and analysis, along with a track record in calibration since 1911. We leverage our extensive historical failure database to accelerate pattern recognition and analysis.
We are proud to be a preferred partner for testing and calibration among regulated industries. Whether you’re in Texas, South Carolina, and North Carolina, we deliver both in-lab testing and on-site calibration solutions to support your critical operations.