Metallurgical Failure Analysis

Responsible for conducting metallurgical investigations and failure analysis of automotive metal components to identify failure mechanisms, determine root causes, and recommend corrective actions. The role supports Quality, R&D, Manufacturing, Supplier Quality, and Field teams by providing technical expertise in materials engineering, testing, and reliability assessment.

Key Responsibilities

• Conduct failure analysis and root cause investigations of automotive and engineering components.
• Perform metallurgical and material characterization tests using laboratory equipment such as:
• Optical Emission Spectrometer (OES)
• Universal Testing Machine (UTM)
• Hardness Testers
• Metallurgical Microscope
• Scanning Electron Microscope (SEM-EDS)
• Evaluate and interpret metallurgical test results to provide technical recommendations and corrective actions.
• Investigate various failure modes including fracture, fatigue, wear, corrosion, cracking, deformation, leakage, overheating, and premature component failures.
• Establish failure mechanisms and identify contributing factors related to material properties, design, manufacturing processes, service conditions, and maintenance practices.
• Possess sound knowledge of manufacturing processes including casting, forging, machining, heat treatment, welding, surface treatment, and assembly processes.
• Provide technical support to Manufacturing, Supplier Quality, and Service teams for in-house and field failure investigations.
• Conduct supplier and field visits for component inspection, evidence collection, process verification, and failure assessment.
• Prepare comprehensive Failure Analysis Reports (FARs) detailing investigation methodology, observations, test results, failure mechanisms, root causes, and preventive actions.
• Ensure compliance with applicable standards such as IATF 16949, ISO/IEC 17025, ASTM, SAE, JIS, DIN, and IS specifications.
• Maintain laboratory equipment, calibration status, testing records, and quality management system requirements.
• Lead laboratory Kaizen, continuous improvement, cost reduction, and standardization activities.
• Coordinate with cross-functional teams to drive effective implementation of corrective and preventive actions (CAPA).

Candidate Profile

Position in Organisation: AM/DM

Qualification

• B.E./B.Tech./M.Tech. in Metallurgical Engineering, Materials Engineering, Mechanical Engineering, or equivalent.

Experience

• Relevant experience of 4 †6 years in automotive failure analysis, metallurgy, material testing, component quality, reliability engineering, or supplier quality management.
• Hands-on experience with metallurgical laboratory equipment and advanced failure investigation techniques.
• Experience in analyzing field failures, customer complaints, warranty issues, and supplier-related quality concerns.

Technical Competencies

• Strong understanding of ferrous and non-ferrous materials and their applications.
• Knowledge of automotive manufacturing processes, material specifications, and heat treatment practices.
• Expertise in metallography, fractography, SEM-EDS analysis, mechanical testing, and root cause analysis tools.
• Familiarity with Core Quality Tools, 8D, FMEA, Fishbone Diagram, Why-Why Analysis, and CAPA methodologies.
• Good understanding of automotive quality systems and laboratory accreditation requirements.

Behavioral Competencies

• Strong analytical and problem-solving skills.