Lonestar offers a wide range of metallurgical services to many diverse industries supported by an experienced team of metallurgical engineers, trained technicians and modern equipment. Lonestar has gained the reputation of providing accurate and timely professional services; particularly when it relates to investigation of metallurgical failures in the Oil and Gas industries.
Metallurgy/Sample Testing
We offer a full spectrum of metallurgical testing in conjunction with our engineering analysis tools to evaluate the root cause of component failure. We have the ability to perform corrosion investigations, surface condition studies, mechanical and fracture mechanics testing and evaluations of weldments. Our testing includes Chemical and Mechanical analysis, Micro & Macro Metallographic Examination, NDT, Specimen Corrosion (transverse/longitudinal) and Hardness Testing.
Component Failure Analysis
Lonestar performs failure analysis by combining materials science with state-of-the-art Optical Microscopy and high resolution digital capture capabilities, thereby helping to determine the root cause of structural failure in metallic components. We investigate industrial materials and equipment involved with industrial accidents, fires and explosions, structural deformations and structural failures.
Origins of Component Failure
Accidents or failures often result from design and/or material imperfections, problems in manufacturing/assembly, component misuse or corrosion. In high temperature applications, complicated failure modes may occur, such as creep ratcheting, rupture and creep fatigue. Our investigations and recommendations will help to prevent costly recurrences, thus lowering operating costs and improving safety.
Metallurgical/Component Failure Report Documentation
Lonestar will provide our clients with the most comprehensive analytical test results, for each of the requested procedures required by the test methods utilized or requested by the client. If needed, high resolution photomicrographs, taken through our in-house state of the art Stereomicroscope/Metallurgical microscope optics and digital capture systems allow Lonestar to provide softcopy and hardcopy evidence of grain measurement/grain expansion/stress related creep damage/specimen crack length(s)/Ferrite measurement/approx. life expectancy.
Metallography and Failure Analysis
| Phase Identification | Point Count Method for Delta Ferrite |
| Grain Size Measurement | Banding Index |
| Inclusion Count | Case Depth Measurement |
| Area/Volume Fraction | Micro Hardness |
| Macro Examination |
Laboratory Metallography & Microscopy
| Energy Dispersive X-Ray Analysis (EDAX) | Scanning Electron Microscopy (SEM) |
| Stereomicroscopy | Fractrography |
Field Metallography
| Replica Metallography | In-situ Metallography (by Replica Technique) |
| Replication of Fractures | Replication of Surface Features |
Corrosion Testing & Evaluation
| Resistance to Pitting and Crevice Corrosion | Susceptibility to Intergranular Corrosion |
| Resistance to Sulfide Stress Cracking (SSC) | Resistance of Hydrogen Induced Cracking (HIC) |
| Examination of Scales & Corrosion Products | Full Ring CAPCIS Test as per OTI 95 635 |
Condition, Usability and Remaining Life Assessment
Lonestar has the necessary versatility, specialization, integrated capability and experience to perform comprehensive inspections necessary for condition, usability and remaining life assessment of a wide range of materials and components used in structures, plants and operating equipment.
- Power Plant & Auxiliary Boiler Tubes, Headers and Connectors
- Turbine Nozzles, Vanes, Combustor Liners and Casings
- Oil and Gas Processing Equipment and Components
- Equipment and Components of Marine/Offshore Structures
- Drilling and Downhole Equipment and Components
- Engine Components
Failure Analysis and Investigation
Failure Analysis and Investigations provide vital information to designers, manufacturers, operators, insurers and loss adjusters to assess/re-assess conditions and take appropriate actions to avert recurrence of failures.
Supported by its integrated analytical facilities and the diverse professional capabilities of its staff, Lonestar has, for the last several years, provided accurate and timely analyses and investigations into failures of components. Reports include comprehensive photographic documentation of observations, discussions of findings, conclusions on the mechanism and root cause of failure.
Stereo Microscopy
- Fracture studies & Analysis
Optical Microscopy
- Study of Metallurgical Micro Structures
Scanning Electron Microscopic (SEM)
- Micro Structural Defect Analysis
Other Metallurgical Related Services
- Assistance in Material selection for intended service
- Assistance in preparation of material testing and inspection Procedures
- Assistance in the study of failure mechanisms of complex systems
- Assistance in Research and Development
- Welding Technology Services
- WPS/PQR Preparation
- Welding Performance & Consumables Qualification Tests
- Troubleshooting in Welding Problems