Structures fail primarily because of fatigue damage. Typical sources of fatigue are restrained thermal expansion, repeatedly applied outside forces and internal vibratory sources. Failure analysis uses stress analysis and strain gage testing to reveal the stress state in the area where the failure started. Coupled with the material's properties, this method can determine if the failure was initiated by low-cycle fatigue or  high-cycle fatigue, or if the crack grew to a critical size and catastrophically failed.

 Failure analysis can also be used to identify contributory factors of product non-performance rotating and reciprocation equipment, such premature component breakage or reduced bearing life. With the incorporation of strain gage testing, failure analysis can identify the source of fatigue damage that, for example, caused a pressure vessel to crack or fan blades to break.

Failure analysis is synonymous with forensic engineering when used in conjunction with expert witness services and litigation support.