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April 24, 2026
Root Cause Investigation · Fracture Analysis · Corrosion Analysis · Material Identification · Cross-Section
ISO/IEC 17025 Accredited | SEM + FTIR + EDX + Cross-Section | Automotive Specialist
When a component fails in production, in qualification testing, or in the field, the questions that matter most are not simply ‘what failed’ but ‘why did it fail’ and ‘how do we ensure it does not fail again.’ Failure analysis is the disciplined forensic process that answers these questions, tracing a visible failure mode back to its physical, chemical, or process root cause.
In the automotive industry, failure analysis is a critical tool across the entire product lifecycle. During development, it identifies design or material weaknesses before they reach production. During qualification, it explains unexpected test failures and guides corrective action. During production, it investigates non-conformances and prevents recurrence. After field returns, it determines warranty liability, informs recall decisions, and drives product improvement.
ALS Testing provides specialist automotive failure analysis services using scanning electron microscopy (SEM), FTIR spectroscopy, energy-dispersive X-ray spectroscopy (EDX), optical microscopy, and metallurgical cross-section preparation. With scanning electron microscopy analysis reaching 260 searches per month in the Malaysian market – the highest search volume in our entire keyword set – this is both the most technically demanding and the most commercially significant capability in our laboratory portfolio.
What Is Failure Analysis?
Failure analysis is the systematic investigation of a component or material to determine the cause of an unexpected failure, non-conformance, or performance deficiency. It applies a structured sequence of analytical techniques, starting with non-destructive visual and optical examination, progressing to surface and interface analysis, and culminating in destructive cross-section and microstructural examination where required, to identify the physical, chemical, or mechanical mechanism responsible for the failure.
In automotive applications, failure analysis encompasses a wide range of failure modes and component types. Fracture analysis investigates cracked or broken metal, polymer, or composite components, determining whether the fracture originated from fatigue, overload, corrosion, embrittlement, or manufacturing defects. Corrosion analysis characterises the type and extent of corrosion damage and identifies contributing factors including material composition, coating quality, and environmental exposure. Delamination and adhesion failure analysis investigates separation at material interfaces including bonded joints, coatings, plated surfaces, and polymer-to-metal bonds. Contamination analysis identifies foreign particles or films on component surfaces or in lubrication systems that have caused or contributed to functional failure.
Failure Analysis in the Automotive Supply Chain
The automotive supply chain applies failure analysis at multiple points where the stakes of unresolved failures are highest. Tier-1 suppliers conduct failure analysis on components returned from OEM qualification testing, where a single test failure can delay programme launch. Warranty teams investigate field returns to distinguish design defects from manufacturing escapes, and to determine whether failures within the warranty period are attributable to the supplier, the assembly process, or the OEM’s application conditions. Purchasing and quality teams use failure analysis to assess whether returned components represent genuine supplier non-conformances or misuse and handling damage by the customer. In each case, the failure analysis report provides objective, evidence-based conclusions that carry weight in technical and commercial disputes.
Why Choose an Accredited Independent Laboratory for Failure Analysis?
Failure analysis conducted by an ISO/IEC 17025 accredited independent laboratory carries a level of credibility that in-house analysis cannot replicate. When failure analysis results are used in OEM disputes, insurance claims, product liability proceedings, or regulatory investigations, the independence and accreditation of the laboratory that produced the analysis is routinely scrutinised. ALS provides analysis that is conducted under a formal quality management system, with documented traceability of methods and equipment calibration, and with the objectivity of an organisation that has no stake in any particular outcome.
Our Failure Analysis Techniques
ALS failure analysis employs a suite of complementary analytical techniques, selected based on the nature of the failure, the material types involved, and the level of detail required to reach a defensible root cause conclusion. Our analysts are experienced in applying these techniques in combination; a fracture surface analysis, for example, may combine optical microscopy for initial characterisation, SEM for high-magnification morphological analysis, and EDX for elemental mapping of fracture features.
Scanning Electron Microscopy (SEM) Analysis
Scanning electron microscopy is the central analytical tool for failure analysis at the micro and nano scale. SEM images component surfaces, fracture faces, and cross-section features at magnifications from 20x to 100,000x, with a depth of field and resolution that far exceeds optical microscopy. SEM analysis reveals fracture morphology, the characteristic features that distinguish fatigue striations from intergranular fracture from ductile overload; identifies surface defects, pits, cracks, and corrosion morphology at the micrometre scale; characterises particle morphology in contamination investigations; and provides the imaging foundation for EDX elemental analysis.
All SEM analysis at ALS is conducted in a controlled environment to minimise contamination, with samples prepared using appropriate techniques for the material type, including gold or carbon sputter coating for non-conducting samples. SEM images are documented with scale bars, magnification, and operating conditions for full traceability in the final report.
Energy-Dispersive X-Ray Spectroscopy (EDX) Elemental Analysis
EDX is used in combination with SEM to provide elemental composition data from specific points, areas, or features on a sample surface. By detecting the characteristic X-rays emitted from a sample under electron beam excitation, EDX identifies which elements are present and at what relative concentrations. In failure analysis, EDX is applied to identify corrosion products (for example, distinguishing chloride-induced pitting from sulfate-driven corrosion), to characterise contaminating particles (distinguishing iron from aluminium from silicon-based particles), to verify coating composition, and to detect elemental segregation or depletion at fracture interfaces.
EDX mapping provides a spatial elemental distribution image across an area of interest, enabling visualisation of where specific elements are concentrated; for example, showing the distribution of zinc in a galvanic corrosion zone, or the localisation of chlorine at a corrosion initiation site.
FTIR Spectroscopy (Fourier Transform Infrared)
FTIR spectroscopy is the primary technique for identification of organic materials, polymers, coatings, and surface films in failure analysis. By measuring the infrared absorption spectrum of a material, FTIR produces a molecular fingerprint that can be matched against reference libraries to identify polymer types, adhesive formulations, lubricant residues, and contaminating films. FTIR is routinely applied in automotive failure analysis to identify: the composition of failed gaskets and seals; contaminating films on metal surfaces that inhibit adhesion or coating bonding; degraded or thermally oxidised polymer components; lubricant composition and degradation state; and foreign material contaminants found at failure sites.
ALS operates both standard FTIR for bulk material analysis and ATR (attenuated total reflectance) FTIR for surface film analysis, enabling characterisation of films as thin as a few micrometres without the need for destructive extraction.
Optical Microscopy & Stereo Microscopy
Optical microscopy at magnifications from 10x to 1000x provides the initial visual characterisation stage of failure analysis, identifying fracture locations, corrosion zones, delamination interfaces, and gross defects before higher-resolution SEM analysis is applied. Stereo microscopy at lower magnifications (7x to 50x) provides three-dimensional surface imaging of fracture faces and component surfaces with excellent depth of field, enabling documentation of large-area failure features in context. All optical microscopy images are captured digitally and documented with magnification and scale information.
Metallurgical Cross-Section Preparation & Analysis
Cross-section preparation involves embedding a component in resin, cutting through the area of interest, grinding and polishing to a metallographic finish, and optionally etching to reveal microstructural features, providing access to the internal structure of a component at the site of failure. Cross-section analysis reveals coating thickness and uniformity, interface integrity between layers, crack propagation paths and morphology, grain structure and phase distribution in metals, porosity and inclusion content in castings, and the presence of decarburisation, carburisation, or other surface treatments. Combined with SEM and EDX analysis of the prepared cross-section, this technique provides the most comprehensive internal characterisation of a failed component.
Failure Modes We Investigate
ALS failure analysis services address the full spectrum of failure modes encountered in automotive component manufacturing and service.
Fracture & Fatigue Failure Analysis
Fracture surfaces carry a detailed record of the failure mechanism, encoded in the morphological features of the fractured faces. Fatigue fractures display characteristic features including fatigue crack initiation sites, beach marks (progression marks showing crack growth over cycles), and fatigue striations at high magnification. Overload fractures show ductile features (dimples, shear lips) or brittle features (cleavage facets, intergranular separation) depending on material and loading conditions. ALS fractography, the systematic analysis of fracture surfaces, determines the failure mode, identifies the initiation site, and assesses whether the failure was consistent with design intent, an unexpected overload, or a material or manufacturing defect.
Corrosion & Surface Degradation Analysis
Corrosion failures in automotive components can take many forms: general uniform corrosion, pitting corrosion localised at surface defects or inclusions, galvanic corrosion at bimetallic interfaces, crevice corrosion in confined geometries, stress corrosion cracking in susceptible alloys under mechanical loading, and fretting corrosion at vibrating contacts. ALS corrosion analysis characterises the corrosion morphology by optical and SEM microscopy, identifies corrosion products by EDX elemental analysis and FTIR spectroscopy, and assesses the contribution of material composition, surface treatment quality, and environmental exposure to the observed damage.
Delamination & Adhesion Failure Analysis
Failures at material interfaces, including between coatings and substrates, bonded surfaces, plated layers and base materials, and moulded polymer overmoulds and metal inserts, are among the most common and commercially significant failures in automotive components. ALS investigates delamination failures by cross-section analysis to characterise the interface morphology, SEM and EDX analysis of both separated surfaces to determine the locus of failure (cohesive failure within a layer, or adhesive failure at the interface), and FTIR analysis to identify contaminating films or inadequate surface preparation that may have compromised adhesion.
Contamination & Foreign Material Analysis
Contaminating particles, films, or deposits on component surfaces can cause a range of functional failures from corrosion initiation to electrical resistance increase to mechanical interference. ALS contamination analysis applies the full suite of SEM, EDX, FTIR, and optical microscopy techniques to characterise contaminants and identify their source. This is frequently applied to investigation of corrosion-related warranty failures where a chloride, sulfate, or organic acid contaminant has initiated pitting or crevice corrosion, and to investigation of electrical contact failures where surface films have increased contact resistance.
Our Failure Analysis Process
ALS failure analysis follows a structured investigation process that ensures comprehensive characterisation and defensible conclusions in every case.
Stage
Activity
Output
1. Receipt & Review
Sample receipt, condition documentation, review of client background information
Sample condition record, investigation brief
2. Non-Destructive Examination
Visual, stereo, and optical microscopy – photographic documentation
Overview images, failure site characterisation
3. Surface Analysis
SEM imaging, EDX elemental analysis, FTIR surface film analysis
High-resolution images, elemental data, material identification
4. Destructive Examination
Cross-section preparation, metallographic analysis, SEM/EDX of cross-section
Internal structure characterisation, interface analysis
5. Data Synthesis
Integration of all analytical data, root cause determination, corrective action guidance
Draft failure analysis report
6. Reporting
Final report with images, data, conclusions, and recommendations
Formal failure analysis report – ISO/IEC 17025 accredited
Frequently Asked Questions – Failure Analysis
Q: What information should I provide when submitting a component for failure analysis?
The quality of a failure analysis investigation is directly related to the quality of the background information provided. When submitting a sample, please provide a description of the component and its function, the failure mode observed such as fracture, corrosion, or delamination, and details on when and how the failure was discovered in production, qualification, or the field. It is also helpful to include the operational history of the component if known, any relevant manufacturing information like material specification, heat treatment, surface treatment, and assembly history, and the specific outcome you require from the investigation. This could include root cause identification, technical evidence for specification compliance, or corrective action recommendations. The more context you provide, the more focused and relevant our investigation can be.
Q: How long does a failure analysis investigation take?
Turnaround time depends on the complexity of the investigation, the number of techniques required, and the current workload of our analytical team. A straightforward fracture analysis using SEM and EDX can typically be completed within five to ten business days. More complex investigations involving cross-section preparation, FTIR analysis, and comparative testing of multiple samples may require two to four weeks. For urgent investigations, particularly production-critical failures, please contact our team directly to discuss expedited options.
Q: Can failure analysis results be used in legal or commercial disputes?
Yes. Failure analysis reports produced by ISO/IEC 17025 accredited laboratories are routinely used as technical evidence in commercial disputes, insurance claims, product liability proceedings, and regulatory investigations. The accreditation of ALS Testing means that our reports are produced under a formally audited quality management system, with documented traceability of methods, equipment, and analyst qualifications. If your investigation has a legal or commercial dimension, please advise our team at the outset so that we can ensure the investigation is conducted and documented to the appropriate standard.
Q: What is SEM analysis and why is it important for failure analysis?
Scanning electron microscopy (SEM) is a technique that uses a focused electron beam to image surfaces at very high magnification and resolution. Unlike optical microscopy, SEM can achieve magnifications of 100,000x or higher with a depth of field that makes it ideal for imaging rough fracture surfaces, corroded surfaces, and three-dimensional microstructural features. SEM is important for failure analysis because it reveals the micro-scale morphological evidence that distinguishes one failure mechanism from another: fatigue striations, cleavage facets, corrosion pits, and particle morphology are all characteristic features that guide the analyst’s conclusion about root cause.
Q: Can ALS analyse plastic, rubber, and composite material failures as well as metals?
Yes. ALS failure analysis services cover metals, polymers, rubbers, composites, adhesives, coatings, and electronics materials. FTIR spectroscopy is our primary tool for polymer and organic material characterisation, enabling identification of polymer type, degradation state, and contaminating species. SEM and EDX analysis are applied to polymer fracture surfaces, interface failures, and contaminant identification in non-metallic components. Our analysts have experience with the full range of materials used in automotive manufacturing.
Request a Failure Analysis Investigation
When a component failure requires expert investigation, ALS Testing provides the analytical depth, accredited methodology, and clear reporting that automotive manufacturers require. Contact our team today to discuss your failure analysis requirements and receive guidance on sample submission.
→ Request a Quote: https://www.alstesting.co.th/request-a-quote/
→ Back to Automotive Testing Hub: /automotive-testing/
ISO/IEC 17025 Accredited | SEM + FTIR + EDX + Cross-Section | Fast Turnaround Available
Read moreApril 24, 2026
Particle Analysis · LPC Counting · Gravimetric Analysis · SEM Particle Identification
ISO/IEC 17025 Accredited | ISO 16232 & VDA 19 Specialist | SEM Particle ID Available
In precision automotive manufacturing, cleanliness is not a finishing step but a fundamental product specification. A single metallic particle of the wrong size in a hydraulic control valve, or a fibre contaminating a fuel injector channel, can translate into field failures, warranty claims, and production shutdowns that cost orders of magnitude more than the testing that would have prevented them.
Technical cleanliness testing – also known as component cleanliness testing or particle contamination analysis, is the validated process of extracting, quantifying, and characterising particulate contamination from the surfaces and internal channels of automotive components. It is governed by two internationally recognised standards: ISO 16232 (Road Vehicles – Cleanliness of Components) and VDA 19 (Testing of Technical Cleanliness – Particulate Contamination of Functionally Relevant Automotive Parts), the German automotive industry standard that is widely required by European OEMs.
ALS Testing is one of the very few independent laboratories in Malaysia and Southeast Asia offering ISO 16232 and VDA 19 cleanliness testing at specialist level. Our capability in this area represents a genuine competitive differentiator for our clients seeking OEM qualification, and for ALS as a laboratory in the regional market.
What Is Technical Cleanliness Testing?
Technical cleanliness testing is a structured analytical process that determines the type, size, and quantity of solid particulate contamination present in or on automotive components. It is applied to precision components where particle contamination poses a functional risk, primarily components with narrow channels, tight clearances, or surfaces that must maintain sealing integrity.
The process involves three core stages: particle extraction, particle quantification, and particle characterisation. Extraction removes particles from the component using a validated method, typically pressure flushing, ultrasonic agitation, or direct surface rinsing with a filtered solvent. Quantification determines the mass and number distribution of extracted particles. Characterisation identifies the morphology and, where required, the material composition of individual particles using microscopy and analytical techniques.
The output of a cleanliness test is a formal cleanliness class, expressed according to the ISO 16232 or VDA 19 classification system. This data allows manufacturers to verify compliance against their own internal specifications or OEM requirements.
Why Technical Cleanliness Matters for Automotive Manufacturers
The drive toward technical cleanliness in automotive manufacturing has been shaped by decades of field failure data linking particulate contamination to premature component failure. Hydraulic control systems in automatic transmissions, anti-lock braking systems, fuel injection systems, power steering units, and turbocharger oil supply circuits are all highly sensitive to particulate contamination. Even particles invisible to the naked eye (particles of 100 microns or less) can cause valve sticking, orifice blockage, accelerated wear, and seal damage.
For electric vehicle powertrains, the stakes are equally high. Battery thermal management systems, power electronics cooling circuits, and electric motor lubrication and cooling pathways all operate with close tolerances where contamination can cause insulation breakdown, thermal hotspots, or mechanical wear. As EV penetration grows in Southeast Asia, the demand for cleanliness testing of EV-specific components is growing alongside it.
OEM requirements for cleanliness compliance are increasingly contractual rather than advisory. Tier-1 suppliers to major European, Japanese, and American OEMs are routinely required to demonstrate cleanliness compliance using data from ISO/IEC 17025 accredited independent laboratories, not in-house testing. This is where ALS plays a critical role in the supply chain quality process.
ISO 16232 vs VDA 19: What Is the Difference?
ISO 16232 and VDA 19 are closely related standards, both governing the testing of technical cleanliness in automotive components. Understanding the relationship between them is important for specifying the correct test method.
Dimension
ISO 16232
VDA 19
Origin
International (ISO Technical Committee 22)
German Automotive Industry (VDA – Verband der Automobilindustrie)
Structure
10-part standard covering extraction, analysis, and reporting
Single comprehensive document – German and English versions
Adoption
Broadly adopted by global OEMs and regulatory frameworks
Required by German OEMs (BMW, Mercedes-Benz, Volkswagen Group, Bosch)
Particle Classes
Uses ISO cleanliness classes based on particle count per size range
Uses VDA cleanliness classes – more granular size range definition
Relationship
Harmonised – VDA 19 Part 1 and ISO 16232 are technically equivalent for most applications
VDA 19 Part 2 adds requirements for assembly environments
Reporting
ISO 16232 format – required for ISO-referencing OEM submissions
VDA 19 format – required for VDA-referencing OEM submissions
In practice, ALS tests to both standards, and our reports can be formatted to meet either ISO 16232 or VDA 19 reporting requirements depending on the OEM specification being addressed. When in doubt, our technical team will advise on the appropriate standard for your specific application.
Our Cleanliness Testing Services
ALS Testing offers a complete suite of technical cleanliness testing services, covering every stage of the analytical process from particle extraction through to SEM-based particle identification. All testing is conducted within our ISO/IEC 17025 accredited scope, with documented quality controls and traceability throughout.
Particle Extraction – Pressure Flush, Ultrasonic & Rinsing Methods
The foundation of any cleanliness test is the particle extraction method. ISO 16232 and VDA 19 define multiple validated extraction methods, each appropriate for different component geometries and contamination scenarios. ALS offers all primary extraction methods, selected in collaboration with the client based on the component design, functional surfaces of interest, and OEM specification requirements.
Pressure flushing is used for components with internal channels such as hydraulic valves, fittings, and manifolds, where a filtered solvent is flushed through under pressure to carry out particles. Ultrasonic extraction is applied to components where particles adhere to external or complex internal surfaces, using ultrasonic energy to dislodge them into a filtration medium. Rinsing extraction is a simpler method for relatively large components where surface contamination is the primary concern. All extraction solvents used are filtered to a level that ensures blank contamination remains below the defined threshold before component testing begins.
Gravimetric Analysis – Total Particle Mass
Gravimetric analysis determines the total mass of particles extracted from a component, expressed in milligrams. This provides a global contamination index that is compared against the mass-based cleanliness specification. The extracted particles are collected on a pre-weighed filter membrane, dried, and weighed on a calibrated analytical balance with traceability to national mass standards. Gravimetric analysis is a fundamental requirement of both ISO 16232 and VDA 19, and provides a clear quantitative index. This result is used by quality control teams to determine if a component meets the predefined mass-based limits for their specific production line.
Light Obscuration Particle Counting (LPC) – Size Distribution Analysis
Light obscuration particle counting (LPC), also known as automatic optical particle counting, provides a count of extracted particles distributed across defined size ranges, expressed as a particle size distribution. A laser-based instrument counts particles suspended in a clean solvent, recording both the total count and the count in each size class (typically 100–150 µm, 150–200 µm, 200–400 µm, 400–600 µm, 600–1000 µm, and >1000 µm). This data is used to assign an ISO 16232 or VDA 19 cleanliness class and to compare against the OEM-specified cleanliness requirement for the component.
LPC is the standard particle quantification method for ISO 16232 and VDA 19 cleanliness testing, and is required for any cleanliness class determination. It provides far more information than gravimetric analysis alone, enabling detection of large individual particles that may pose functional risk even when total particle mass is low.
Microscopic Particle Analysis & Classification
Following LPC, particles collected on the filter membrane are examined under a calibrated microscope (typically at 50x or 100x magnification) to classify individual particles by type, morphology, and size. ISO 16232 and VDA 19 define particle classification categories: metallic shiny (reflective metallic particles), metallic non-shiny (oxide-coated or corroded metals), fibres, and other non-metallic particles. This classification is important because different particle types carry different risk profiles; a metallic shiny particle of 400 µm in a hydraulic valve is far more concerning than a fibre of the same size.
Microscopic analysis is reported with representative photomicrographs of significant particles, providing visual evidence of the contamination types found. This information supports root cause investigation when cleanliness failures are identified.
SEM-EDX Particle Identification
For cases where the identity of individual particles must be confirmed, particularly in failure investigation, contamination source tracing, or where OEM specifications require elemental identification of particles exceeding a defined size. ALS offers scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDX) analysis of individual particles collected from the filter membrane.
SEM imaging provides high-magnification morphological characterisation of individual particles, while EDX provides elemental composition data that enables positive identification of particle material, for example distinguishing iron from aluminium from stainless steel, or identifying ceramic, glass, or polymer particle types. This combined SEM-EDX analysis is the most powerful particle identification tool available and provides definitive evidence for contamination source investigation.
Component Types We Test
ALS cleanliness testing services cover the full range of precision automotive components for which cleanliness specifications are typically defined by OEMs or international standards. Our experience spans hydraulic systems, powertrain components, fuel systems, braking systems, and EV-specific assemblies.
Hydraulic & Fluid Power Components
Hydraulic valves, valve bodies, manifolds, pump housings, cylinders, fittings, and tubing, all of which operate with fluid clearances where particulate contamination can cause sticking, jamming, or accelerated wear of precision-ground surfaces. ALS is experienced in testing components for automatic transmission hydraulic circuits, power steering systems, and industrial hydraulic assemblies to ISO 16232 and VDA 19 specifications.
Fuel System Components
Fuel injectors, fuel rails, fuel pumps, and direct injection components require extremely high cleanliness standards, as contamination can cause injector nozzle blockage, irregular spray patterns, and combustion chamber damage. Cleanliness requirements for high-pressure direct injection fuel systems are among the most stringent in automotive manufacturing, often requiring cleanliness classes that exclude particles above 100–200 µm.
Braking System Components
ABS modulators, brake calipers, master cylinders, and hydraulic brake lines must meet cleanliness specifications that protect the fine orifices and seal surfaces critical to braking system integrity. ALS tests braking components to OEM cleanliness specifications and ISO 16232, with particular attention to metallic particle counts that indicate machining residue or wear debris.
EV & Powertrain Components
Electric motor housings, battery thermal management circuit components, power electronics cooling plate assemblies, and EV gearbox components all require cleanliness verification as EV production scales up across the region. ALS is developing and applying cleanliness testing protocols for EV-specific components, drawing on our ISO 16232 expertise and engaging with emerging OEM specifications for EV powertrain cleanliness.
Standards & Test Methods
Our cleanliness testing is conducted to the following primary standards and test methods, all within our ISO/IEC 17025:2017 accredited scope. For tests outside our accredited scope, we apply validated in-house methods following the principles and protocols established by ISO 16232 and VDA 19.
Standard / Method
Description
Application
ISO 16232
Road Vehicles – Cleanliness of Components (10 parts)
International cleanliness standard for all automotive components
VDA 19 Part 1
Testing of Technical Cleanliness – Particle Contamination Analysis
German OEM requirement – BMW, VW Group, Mercedes-Benz, Bosch
VDA 19 Part 2
Assembly Environment Requirements for Technical Cleanliness
Clean area requirements for assembly processes
Gravimetric Analysis
Total extracted particle mass by calibrated weighing
Quantitative mass measurement for comparison against customer-defined limits.
Light Obscuration Particle Counting (LPC)
Automated particle count by size class using laser obscuration
Particle size distribution – ISO/VDA cleanliness class assignment
Microscopic Particle Classification
Manual classification of particles by type and morphology
Particle type distribution – metallic, fibre, non-metallic
SEM-EDX Particle ID
SEM imaging + elemental analysis of individual particles
Particle source identification, failure investigation, OEM requirement
Why Choose ALS for Cleanliness Testing?
Technical cleanliness testing is a specialised capability that requires more than a particle counter and a filter membrane. It requires experienced analysts who understand automotive manufacturing processes, validated extraction methods appropriate to the component type, calibrated equipment with documented traceability, and a quality management system that ensures the reliability of every result.
One of Very Few Specialists in Malaysia & SEA
ALS is one of very few independent laboratories in Malaysia and Southeast Asia offering ISO 16232 and VDA 19 cleanliness testing at this level of depth. While general testing laboratories may offer particle counting services, the full cleanliness testing process, including validated extraction, gravimetric analysis, LPC, microscopic classification, and SEM-EDX particle identification, which requires specific expertise and investment that ALS has made and maintains.
Full Process Capability from Extraction to SEM-EDX
Unlike laboratories that offer only partial cleanliness testing capability, ALS provides the complete analytical workflow from sample reception and extraction method selection through to final report with SEM-EDX particle identification where required. This full-process capability means that you can manage your entire cleanliness testing requirement through a single laboratory relationship, with consistent methods and results across all your components and platforms.
ISO/IEC 17025 Accredited Results
Our ISO/IEC 17025:2017 accreditation covers cleanliness testing within our accredited scope, meaning that our results carry the formal weight of internationally recognised laboratory accreditation. For OEM submissions and qualification programmes that require accredited test data, ALS test reports satisfy this requirement without question.
Frequently Asked Questions – Cleanliness Testing
Q: What is technical cleanliness testing and why do automotive OEMs require it?
Technical cleanliness testing is the validated process of extracting, quantifying, and characterising particulate contamination from automotive components. OEMs require it because particulate contamination in precision components, particularly hydraulic systems, fuel systems, and braking systems, is a leading cause of field failures and warranty claims. ISO 16232 and VDA 19 provide the standardised framework for cleanliness specification and verification, and OEMs contractually require Tier-1 suppliers to demonstrate compliance using data from accredited independent laboratories.
Q: What is the difference between ISO 16232 and VDA 19?
ISO 16232 is the international standard for automotive component cleanliness testing, developed by ISO Technical Committee 22. VDA 19 is the German automotive industry standard, developed by the VDA (German Association of the Automotive Industry), and is specifically required by German OEMs such as BMW, Volkswagen Group, and Mercedes-Benz, and their major suppliers. The two standards are harmonised: VDA 19 Part 1 is technically aligned with ISO 16232, but the reporting formats and classification systems differ. ALS can test to either standard and can format reports to meet your specific OEM submission requirement.
Q: What types of particles are identified in a cleanliness test?
ISO 16232 and VDA 19 define four primary particle types: metallic shiny particles (highly reflective metals such as machined steel or aluminium), metallic non-shiny particles (oxide-coated or corroded metals, cast particles), fibres (organic or synthetic fibres from wipes, clothing, or seals), and other non-metallic particles (rubber, ceramic, glass, polymer). SEM-EDX analysis can further identify the elemental composition of individual particles for definitive material identification.
Q: How do I prepare my components for cleanliness testing submission?
Component preparation and packaging are important to avoid contamination between manufacturing and laboratory testing. In general, components should be sealed in clean polythene bags immediately after manufacture and kept sealed until sample submission. Do not use paper or cardboard packaging in contact with the component surface. Please contact our team before submission and we will provide specific sample packaging and shipping instructions for your component type.
Q: Can ALS test to OEM-specific cleanliness specifications?
Yes. ALS has experience with a range of OEM-specific cleanliness specifications in addition to the ISO 16232 and VDA 19 standards. Please provide the OEM specification document number and revision when making your enquiry, and our technical team will confirm our capability and advise on the test programme required.
Request a Cleanliness Testing Quote
Whether you are seeking ISO 16232 certification for a new component programme, investigating a cleanliness-related field failure, or establishing a cleanliness testing protocol for a new product line, ALS Testing has the expertise and accreditation to support you. Contact our team today to discuss your requirements and receive a quotation.
→ Request a Quote: https://www.alstesting.co.th/request-a-quote/
→ Back to Automotive Testing Hub: /automotive-testing/
ISO/IEC 17025 Accredited | ISO 16232 & VDA 19 Specialist | SEM-EDX Particle ID Available
Read moreApril 17, 2026
Dust analysis in factories: testing methods and ISO standards that factories need to know.
The growth of the EV and semiconductor industries has made particle control in manufacturing lines a key global issue, with the particle analysis services market valued at over $1 billion and expected to grow at an average rate of over 8% per year.
Particle analysis is the process of examining the size, quantity, and composition of particulate matter contaminating air, surfaces, or product components. This is done to assess risk and ensure quality control meets industry standards. Many manufacturing industries require strict air cleanliness control according to ISO 14644 standards.
This article will help you understand how dust analysis works, the types of instruments used, and why particle control has become a core part of quality control in modern factories.
Why is the Particle Analysis Market Growing So Rapidly?
Controlling particle contamination is a critical issue in advanced industries, particularly semiconductor and electronics manufacturing, which require cleanrooms with strict particle control.
According to global industry organizations, the particle analysis services market is worth over a billion dollars and is growing at an average rate of 8–9% per year.
This growth is primarily driven by three factors:
Quality and hygiene regulations in industry.
The growth of the EV and semiconductor industries.
Continuously evolving analytical technologies such as AI and real-time monitoring systems.
As production lines become more complex, dust analysis has become an integral part of quality control systems, not just general environmental monitoring.
The Dust Situation in Thailand: From PM2.5 to Production Processes
Thailand faces a recurring PM2.5 dust problem. Data from the Pollution Control Department (PCD) indicates that many areas of the country have annual PM2.5 averages higher than the World Health Organization’s guideline of 5 micrograms per cubic meter, as per WHO Air Quality Guidelines.
The PCD report also states that PM2.5 sources in Thailand come from various sectors, such as:
Transportation
Open burning
Industrial sector
Energy production
While PM2.5 information is often discussed in a health context, in the manufacturing sector, process particles are also a significant risk.
These particles can originate from metal scraps from machining, plastic powder from molding, or dust from machine wear, and can directly affect product quality.
How many types of dust are there in a production line, and how do they differ?
In industry, dust analysis is divided into two main groups based on particle origin: Airborne Particles and Component Cleanliness, which require different testing methods and reference standards.
Airborne Particles
Component Cleanliness
Type
Floating in the air in the production area.
Stuck on a surface or in a part.
Main factors
From the movement of people, machinery, and manufacturing processes.
From metal scraps, plastic powder, and wear and tear dust.
Main industry
Semiconductor, Medical Devices, Cleanroom
Automotive, EV, and Automotive parts
Standard
ISO 14644
VDA 19 / ISO 16232
Testing
LPC, Optical Microscope
SEM/EDX, Optical Microscope, IC
ALS
✓
✓
As manufacturing processes become more complex, dust monitoring has become part of a quality control system, not just an environmental test.
Laboratory Dust Analysis Methods
Laboratory dust analysis uses a variety of instruments depending on the particle characteristics and the context of the manufacturing process, including:
Optical Microscope
SEM/EDX (Scanning Electron Microscope with Energy Dispersive X-ray)
LPC Particle Counter (Liquid Particle Counter)
GC-MS (Gas Chromatography–Mass Spectrometry)
Ion Chromatography (IC)
Standards used in industrial dust analysis
Industrial particulate matter analysis must adhere to internationally recognized standards so that test results can be used in quality control and inspection processes.
Commonly encountered standards include:
Automotive & EV
Semiconductors and Electronics
Medical Devices
Aerospace
Food & Pharmaceutical
How long does dust analysis take?
The timeframe depends on the testing method. For example,
particulate matter measurement using ISO16232/VDA19 may take approximately 7-10 business days.
In an era of increasingly stringent manufacturing standards, the visibility and control of particles in production processes have become an integral part of a factory’s quality management system. Dust analysis is not just a technical test; it’s a crucial tool that helps manufacturers understand production process risks and consistently maintain international product standards.
For dust analysis or particle monitoring in your production process, ALS Testing Services (Thailand) Co., Ltd. offers services with an ISO/IEC 17025 certified laboratory.
Read moreOctober 21, 2024
June 20, 2024
