How do you conduct a failure analysis on a heat exchanger tube that has leaked?

Analysis steps: document failure location and operating history, preserve failed samples for metallurgical analysis, examine visually (external corrosion, erosion patterns, mechanical damage), perform dimensional measurements (wall thinning pattern), conduct metallurgical examination (microstructure, crack morphology, deposit analysis). Common failure modes: erosion-corrosion at inlet, stress corrosion cracking (specific environments), fatigue (vibration), pitting (under deposits), and dezincification (brass). Root cause determines corrective action: material upgrade, process changes, design modifications, or operational improvements.