Failure analysis is the process of collecting and analyzing data to determine the cause of a failure and how to prevent it from recurring. It is an important discipline in many branches of manufacturing industry, where it is a vital tool used in the development of new products and for the improvement of existing products.

Failure analysis and prevention are important functions to all of the engineering disciplines. The materials engineer often plays a lead role in the analysis of failures, whether a component or product fails in service or if failure occurs in manufacturing or during production processing. In any case, one must determine the cause of failure to prevent future occurrence, and to improve the performance of the device, component or structure.

As for examples of the application of failure analysis involves the aerospace industry, aircraft accidents are remembered by the public because of the unusually high loss of life and broad extent of damage that is typical of this type of accident. On December 19, 2005, just off Miami Beach, Florida, a Grumman G73T Turbo Mallard seaplane crashed as it was taking off. This aircraft was carrying 15 passengers, 3 infants and a crew of two. There was an explosion and fire and the right wing separated prior to the plane impacting the water. Examination of the wreckage revealed fatigue cracks in the right wing. The cause of the accident is still under investigation. However, structural failure, initiated by fatigue is suspect.