A wide variety of failures can cause physical damage to storage media, which may result from human errors and natural disasters. CD-ROMs can have their metallic substrate or dye layer scratched off; hard disks can suffer from a multitude of mechanical failures, such as head crashes and failed motors; tapes can simply break.
Physical damage to a hard drive, even in cases where a head crash has occurred, does not necessarily mean there will be permanent loss of data. The techniques employed by many professional data recovery companies can typically salvage most, if not all, of the data that had been lost when the failure occurred.
Of course there are exceptions to this, such as cases where severe damage to the hard drive platters may have occurred. However, if the hard drive can be repaired and a full image or clone created, then the logical file structure can be rebuilt in most instances.
Most physical damage cannot be repaired by end users. For example, opening a hard disk drive in a normal environment can allow airborne dust to settle on the platter and become caught between the platter and the read/write head. During normal operation, read/write heads float 3 to 6 nanometers above the platter surface, and the average dust particles found in a normal environment are typically around 30,000 nanometers in diameter.^[1] When these dust particles get caught between the read/write heads and the platter, they can cause new head crashes that further damage the platter and thus compromise the recovery process. Furthermore, end users generally do not have the hardware or technical expertise required to make these repairs. Consequently, data recovery companies are often employed to salvage important data with the more reputable ones using class 100 dust- and static-free cleanrooms.^[2]

Recovery techniques

Recovering data from physically damaged hardware can involve multiple techniques.^[3] Some damage can be repaired by replacing parts in the hard disk. This alone may make the disk usable, but there may still be logical damage. A specialized disk-imaging procedure is used to recover every readable bit from the surface. Once this image is acquired and saved on a reliable medium, the image can be safely analyzed for logical damage and will possibly allow much of the original file system to be reconstructed.

Hardware repair

Media that has suffered a catastrophic electronic failure requires data recovery in order to salvage its contents.

A common misconception is that a damaged printed circuit board (PCB) may be simply replaced during recovery procedures by an identical PCB from a healthy drive. While this may work in rare circumstances on hard disk drives manufactured before 2003, it will not work on newer drives. Electronics boards of modern drives usually contain drive-specific adaptation data (generally a map of bad sectors and tuning parameters) and other information required to properly access data on the drive. Replacement boards often need this information to effectively recover all of the data. The replacement board may need to be reprogrammed. Some manufacturers (Seagate, for example) store this information on a serial EEPROM chip, which can be removed and transferred to the replacement board.^[4][5]
Each hard disk drive has what is called a system area or service area; this portion of the drive, which is not directly accessible to the end user, usually contains drive's firmware and adaptive data that helps the drive operate within normal parameters.^[6] One function of the system area is to log defective sectors within the drive; essentially telling the drive where it can and cannot write data.
The sector lists are also stored on various chips attached to the PCB, and they are unique to each hard disk drive. If the data on the PCB do not match what is stored on the platter, then the drive will not calibrate properly.^[7] In most cases the drive heads will click because they are unable to find the data matching what is stored on the PCB.