The relationship between composition, structure, properties and performance is central to the design, use and failure analysis of engineering components. Thermogravimetric analysis (TGA) and wavelength X-ray fluorescence (WRXF) were applied in evaluating the elemental composition and thermal properties, respectively, of a failed abrasive cut-off wheel. The cutting tool, consisting of a bonded abrasive disc, failed prematurely during the routine sectioning of a steel member. The operator was injured as a result. Analysis indicated an improper mixture of the organic constituents comprising the wheel bonding material. Instead of the uniform wear anticipated under normal cutting conditions, the improper mixture resulted in a degradation of the wheel's mechanical properties, and catastrophic brittle fracture.