Testing Machines andSystems for Metals

Intelligent Testing

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Testing Systems

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Table of Contents

1 The Zwick Roell Group ..................................................................................................................................... 3

2 Metals – Use and Properties ............................................................................................................................. 4

3 Tests in the Metal Industry ................................................................................................................................ 63.1 Heavy Plate ............................................................................................................................................. 73.2 Strip and Sheet ...................................................................................................................................... 113.3 Thin Sheets ............................................................................................................................................ 133.4 Bars and Rods ....................................................................................................................................... 163.5 Section and Reinforcing Steel ................................................................................................................. 183.6 Wire and Cable ...................................................................................................................................... 213.7 Pipes ..................................................................................................................................................... 233.8 Castings and Forgings ............................................................................................................................ 253.9 Fasteners ............................................................................................................................................... 26

4 Quasi-Static Materials Testing: Products and Services ..................................................................................... 284.1 Material Testing Machines ....................................................................................................................... 284.2 Drives for Quasi-Static Testing Situations ................................................................................................. 304.3 Sheet Metal Testing Machines ................................................................................................................ 334.4 Hardness Testing Machines and Instruments ........................................................................................... 344.5 Measurement and Control Electronics ..................................................................................................... 384.6 testXpert® II ............................................................................................................................................ 394.7 Load Cells .............................................................................................................................................. 424.8 Specimen Grips ...................................................................................................................................... 434.9 Extensometers ....................................................................................................................................... 454.10 High-temperature Testing Accessories .................................................................................................... 494.11 Creep Test ............................................................................................................................................. 504.12 Robotic Testing Systems......................................................................................................................... 514.13 Specimen Preperation ............................................................................................................................ 54

5 Fatigue Strength and Dynamic Strength Testing: Products and Services .......................................................... 555.1 Fatigue Testing Machines ....................................................................................................................... 555.2 Impact Stregth Testing Machines ............................................................................................................ 59

6 Modernization Packages for all Makes of Materials Testing Machines ............................................................... 63

7 Zwick Services ............................................................................................................................................... 64

8 Standards and Testing Devices ....................................................................................................................... 68

This brochure provides an overviewof devices, machines and systems ofthe Zwick Roell AG for the testing ofmetals in the corresponding indus-tries, research and development,production, quality assucrance, testinstitutes and training centers.

As such this represents only a partof our comprehensive overall pro-gram.

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Fig 1: The headquarter of the Zwick Roell AG and the Zwick GmbH & Co. KG at Ulm, Germany

By acquisition of the German com-pany GTM (2006) and the Austriancompany Messphysik (2007) theknow-how of the Zwick Roell AG inthe field of force and elongationmeasurement has been safed andenriched.

Zwick has many years of experi-ence, combined with a multitude ofsupplied systems, and this experi-ence is continuously supplementedby constant communication withcustomers. On this solid base thecompany supplies a wide range ofhigh-performance products – fromthe economical standard quality

control machine up to customisedsolutions designs for specific testrequirements. Modern mechanics,high-performance electronics andthe application-oriented software arethe prerequisite for the versatility andthe high “intelligence” of these mo-dern testing machines and systems.

The services of the Zwick Roell AGgo far beyond the supply of prod-ucts. In 1994 the company receivedits certification ISO 9001 accreditedhelping to guarantee a consistentlyhigh product and service quality.With its accredited calibration lab-oratories, the companies of theZwick Roell AG are able to verify andcalibrate test systems and to issueinternationally recognized certificates.

1 The Zwick Roell AG –more than a centuryof experience inmaterials testing

Mechanical-technological testing isone of the oldest disciplines ofmaterials testing. As early as in the15th and 16th century, Leonardo daVinci and Galileo Galilei were alreadyconsidering the flexural stressing andelastic behaviour of materials.In the course of time further know-ledge was obtained. In the middle ofthe 18th century the first testing ma-chines finally appeared in France.

Since 1920 the company Roell &Korthaus was involved in the materialstesting business. In 1937 Zwick builtits first testing machines and sys-tems for mechanical testing of mate-rials, and many years prior to that in1876, a Professor Seger had foundeda chemical laboratory as part of ascientific technological consultingcompany for non-metallic materials.During the 20th century the presentcompany, Toni Technik, has evolvedfrom these origins and is now con-sidered a leading expert in testsystems for building materials. MFL(Mohr & Federhaff) – a company thatwas founded in 1870 – became partof the Zwick Roell group and interest-ingly, Carl Benz (of Mercedes Benzfame) was one of their employees.

Since 1992, these companies haveformed the Zwick Roell group, and inJuly 2001, the company group wasconverted into a stock corpo-ration:the Zwick Roell AG. Part of thisstock corporation are the companiesZwick, Toni Technik, Indentec Ltd.,and since may 2002 Acmel Labo.These companies supply an extensiveprogram for materials, component,and functional tests – from the man-ually operated hardness tester up toa complex robotic test systems forthe twenty-four-seven productioncontrol.

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2 Metals – Use andProperties

The properties of metallic materials –metals and metal alloys – cover avery broad spectrum. The distinctionbetween function and structure alsoapplies to materials; examples ofstructural and construction materialsinclude materials for machine andplant building, precision engineeringand civil engineering, while functionalmaterials are used in areas such aselectrical engineering, electronicsand media technology.

With construction materials theemphasis is on mechanical proper-ties such as strength, rigidity(elasticity) and ductility (plasticity) atworking temperature. Thesecharacteristics are the main influ-ence in testing-machine design(maximum required test load for loadframes and load cells) and equip-ment (high-resolution extensometersfor Young’s Modulus determination).

As an illustration, steel undermechanical loading displays veryhigh stiffness right from the beginningof the test – unlike rubber, forexample. This results in large loadincreases for very small deforma-tions, often less than a hairsbreadth.These deformations are elastic anddecrease again with load reduction.Only when the load is furtherincreased is a plastic (i.e. perma-nent) deformation superimposed onthe elastic deformation.

Specimens of very brittle materials(such as cast iron) or soft steels atlow temperatures fracture withoutwarning on reaching cohesivestrength (i.e. with no prior necking).

Fig. 1: Load-extension curve of sheet-steel tensile specimen (upper) and enlarged view ofthe area until just after 0.2 % proof stress (lower)

By contrast, local stiffness in toughmaterials decreases sharply after theelastic limit has been exceeded andcan even reach values of zero orless (increase in deformation withoutload increase or even with loadreduction).

The load-extension curve of a steel-sheet tensile specimen (gage lengthL0 = 80 mm) illustrates very well thechange in stiffness as deformationincreases.

Table: Comparison of Specific Material PropertiesMaterial properties Metals Concrete Plastic mat.(without extreme values) (non-reinforc.)

• Tensile and compressionstrength [MPa] 100 ... 2000 200 ... 500 20 ... 160

• Young’s Modulus [GPa] 70 ... 210 15 ... 40 0,06 ... 6• Density (specific weigth) [g/cm³] 2,7 ... 7,8 2,1 ... 2,4 1 ... 2

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Fig. 1: Stress-strain/crosshead travel curve of a tensile specimen made of steel sheet (testedwith a Zwick Z100 materials testing machine with hydraulic specimen grips)

The purely elastic strain up to theelasticity limit is only approx. 0.06 %(approx. 50 µm); by contrast theplastic strain up to failure is almost32 % (approx. 26 mm) – more than500 times greater! This imposesparticular requirements on theextensometer used in the same testto determine the slope of the straightline in Hooke’s Law (Young’sModulus), the proof stress, the strainat maximum force and the strain atbreak - high resolution and largedisplacement measurement are es-sential. Additionally, the measurementsystem must not be damaged by asudden specimen break.

It is not only the specimen thatdeforms under the influence of thetest load. All components located inthe load train of the testing machine(load frame, load cell, specimen gripsand the parts of the specimen out-side the gage length) also deform –but only elastically. For specimenswith high stiffness, the elastic defor-mation of the testing machine tendsto be significantly greater (up to tentimes) than that of the specimen.

Indirect strain measurement viacrosshead or piston travel is there-fore much too imprecise to measurethe slope of Hooke’s lines and thecorresponding proof stress.

The crosshead or piston travel of thetesting machine is distributedbetween specimen and machinedeformation according to the ratio ofspecimen stiffness to machinestiffness. The deformation rate isthus not only dependent on cross-head or piston speed, but also onthe specimen (stiffness, geometry)and on machine configuration.

Test results, particularly for softermaterials, are affected by defor-mation rate, so comparability of testresults from specimens of differentdimensions or between differentmachines can only be guaranteed ifthe crosshead or piston speed is setor regulated (in accordance with themeasured load or deformation) toallow comparable deformation rates.

Testing Standards – Essentialfor Comparable Results

A fundamental role of testingstandards lies in creating the sameconditions for specimen and testsequence, regardless of when,where and what is being tested. Theinternational standards, which areincreasingly replacing nationalstandards, are an essential step tofurther improving the comparability oftest results. The tables from page 67onwards summarize the principal na-tional and international standardsused today for testing metals.As a rule the standards are reviewedevery five years and also amended ifapplications to do so have beenreceived and a majority of thestandards committee are in favor.Zwick Roell employees are active onseveral standards committees,bringing the specialist knowledgeand experience of a testing machinemanufacturer to the table and at thesame time keeping their knowledgeup to date for product developmentand specialist advice to customers.

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Metal industry segments

Flat products

Heavy plate(plus slabs and billets)

Strip and sheet(plus hot-rolled strip and hot-rolled plate)

Thin sheet(plus tinplate and hot-galvanized sheet)

Long products

Bar and rod

Sections andreinforcing steel

Wire and cable

Near-net-shape products

Pipes(plus fittings)

Castings and forgings(plus sintered metal and powder metallurgy components)

Fasteners(plus welding and joining technology)

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3 Tests in the Metal Industry

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3.1 Heavy Plate

Heavy plates are steel sheets with awidth of up to four meters and athickness of at least five millimeters,up to approx. 250 mm. They areused principally in the constructionindustry, for heavy plant and cranes,in shipbuilding, for offshore drillingplatforms and for large-diameter,thick-walled pipes.

Hardness Testing

Hardness testing to Brinell up to testloads of 29,000 N can be performedwith ZHU topLine series hardnesstesting machines. This range featuresstate-of-the-art technology, employ-ing a zoom lens, CCD camera andLCD display, with high reproducibilityensured by the automatic testsequence and closed-loop tech-nology. For Brinell tests the ringlightoption offers a further increase inmeasurement accuracy. Zwick alsohas instruments available for portablehardness testing and for all hardnesstesting methods to Vickers (p. 34onwards).

Tensile Test

Tensile specimens are removed fromheavy plate in such a way that thesheet thickness is retained as speci-men thickness as far as possible.Specimens have a correspondinglylarge cross-section, the parallel lengthbeing produced by milling. The tensiletest material properties are thereforedetermined over a large volume andthe influences of specimen productionminimized. Zwick’s wide range ofstandard testing systems up to 2500kN provide high-accuracy testingunder high loads; our hydraulicspecimen grips ensure that perfectclamping and positioning of specimensare maintained during tests. Strainmeasurement in most cases is via aMacro digital extensometer, offering ahigh degree of robustness – itssensor arms remain on the specimenuntil failure. It also features easyoperation; the sensor arms areapplied automatically at the start ofthe test and can be placed in a safeidle position at the end. The highmeasurement accuracy (up to ISO9513 Class 0.5) is not affected byoxide layers and gage length (L0)adjustment can be performedautomatically via the testing software.

Fig. 1: Heavy plate specimen with macroextensometer

Fig. 2: ZHU3000topLine Universal hardnesstesting machine

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Robotic Testing Systems forTensile Tests

The safe, reliable and precisehandling of heavy specimens placesconsiderable demands on theoperator and the operating system.

Zwick’s robotic testing solutionscompletely automate the testingprocess while relieving the load onoperators, minimizing operator errorsand increasing operational safetyand reliability. Under our robotic

testing concept, the specimens fortesting are sorted into magazinesmanually, but from this pointeverything takes place automaticallyup to sorting of the specimenremains for inspection if necessary.Additional measuring devices can beintegrated into the sequence asrequired, in particular Zwick’s cross-section measuring device with fourindependent, automatically appliedmeasuring transducers for precisecross-sectional area determination.

Fig. 2: Heavy plate specimen in automaticcross-section measuring device (QMG)

Fig. 1: Automated tensile testing of heavy plates (roboTest B)

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Fig. 1: CT specimen in Vibrophore (HFP)

Fig. 2: SENB specimen in Vibrophore (HFP)

Fracture MechanicsKIc Determination

Fracture toughness KIc is an impor-tant material property for metallicmaterials in safety-related applica-tions such as aircraft construction,power-station building and automobi-le manufacturing and is determinedusing a specimen into which anartificial crack has been introduced.The specimen is loaded until failureand the fracture toughness KIc isdetermined from the load-deformationcurve and the crack length. Detailsof the test procedure are containedin the relevant standard (ASTM E 399)and the two-stage test can be per-formed very efficiently using ZwickVibrophores (HFP). Crack formationin the specimen is instigated by themechanically produced notchfollowed by cyclic loading. The highfrequency used allows rapidgeneration of a defined crack (‘pre-cracking’) and the process is highlyreproducible, thanks to the highsensitivity of the resonant frequencyto crack formation. The specimengeometry most frequently used isillustrated in Fig. 1; the specimen isknown as a CT (Compact Tension)specimen. The load is appliedthrough pins inserted into holes inthe specimen, giving a mixed tensileand flexure loading. Flexure speci-mens (known as SENB specimens,Fig. 2) are also used. While thetesting method is simpler for theflexure specimen than the CTspecimen, the required specimenvolume is significantly greater. This isclearly shown in the illustrations.

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Charpy Impact Test

Notched impact strength is an im-portant characteristic for applicationsin pipeline construction and ship-building and can be determined withCharpy specimens in pendulumimpact testers. The standardizednotched specimens are inserted byhand, by means of simple feedingdevices, or using robotic systemsand impacted with energies up to750 J. Zwick supplies temperatureconditioning systems for correctconditioning of specimens down to-180 °C. Under the MachineryDirective, pendulum impact testeroperation is subject to strict safetyrequirements, which are easily metby Zwick’s safety housing andsophisticated safety technology.

Pellini Drop-Weight Test

Zwick Pellini drop-weight testers areused to investigate the influences ofa weld on crack formation in steelmaterials. Conditioned standardizedspecimens are impacted up to1650 J, with manual opticalevaluation of crack formation orbreak, depending on the specimentemperature selected.

Fig. 1: RKP 450 pendulum impact tester (Inset: anvil)

Fig. 2: Pellini drop-weight tester

Additional Tests for HeavyPlates:

• Tensile test at elevatedtemperature

• Creep tests• Flexure and compression tests• Shear tests/weld seam tests• Fatigue tests• Rotating bar bending fatigue tests

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3.2 Strip and Sheet

Strip refers to steel and non-ferrousproducts which are rolled into coils,e.g. hot-rolled strip, which is used asprimary material for cold-rolledsheets. Hot-rolled strip is producedin thicknesses up to 15 mm and inwidths up to 2200 mm. Hot-rolledplate is sheets cut out of hot-rolledstrip and is up to 15 mm thick andup to 2000 mm wide.

Tensile Tests with r- and n-ValueDetermination

r- and n-values are often also deter-mined in tensile tests in order tocharacterize forming properties; then-value describes the workhardening – increase in stress –during plastic deformation up to uni-form elongation, while the r-valuedescribes the vertical anisotropy. Then-value is determined from thetensile stress data and strain values;for the r-value the transverse strainon the tensile specimen is addition-ally measured. Tensile specimensare taken from the strip or sheet atset angles to the rolling direction.

One factor affecting the r-value isthe rolling direction. The sheetthickness is retained as specimenthickness, while the parallel length isproduced by milling or punching plusfinishing.

Zwick supplies a wide range ofstandard testing systems for deter-mining material properties fromtensile tests; these systems providehigh-precision testing under high

loads. Our comprehensive range ofaxial and transverse strain extenso-meters provide the optimum combi-nation according to the customer’srequirements and testing conditions,e.g. a Macro digital extensometercombined with an optical transversestrain extensometer. This combinationis noted for robustness and a highlevel of automation plus easy speci-men handling. Both extensometersmeasure up to specimen break.

Biaxial Tensile Test

The biaxial tensile test is used todetermine the deformation charac-teristics of materials. This test isused primarily for research anddevelopment as it allows definedstress values in the intersection areaof the specimen to be set up andinvestigated. These testing machinesare produced to customers’ require-ments. Strain measurement isperformed using non-contactextensometry in most cases andZwick provides several solutions forthis; measurement of strain distri-bution is available via collaborationwith Zwick’s specialist partners.

Fig 1: Traverse strain extensometer: videoXtens; an axial strain extensometer: macro Fig 2: Biaxial tensile test

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3-Point Flexure Test

The 3-point flexure test is used fordetermining flexural properties andfor visual assessment of the bendingedge, an important aspect of theflexure test being visual evaluation ofthe behavior of weld seams. Zwick’srange of flexure test kit optionscombined with adaptations toexisting specimen holders providesan ideal solution.

High-temperature Tests

In applications such as engine manu-facture, power station constructionand chemical plants, material be-havior at elevated temperatures (upto approx. 1200 °C) is of vital impor-tance, calling for high-temperaturetensile testing and, to a lesser extent,flexure testing. Zwick’s solutions forthese tests comprise temperature-controlled furnaces, specimen pull-rods, high-temperature strainmeasurement and other essentialaccessories for integration into Zwicktesting machines.

Fig. 3: High-temperature flexure test infurnace

Fig. 1: 3-point flexure test kit for metal strip

Fig. 2: Hot tensile test in high-temperaturefurnace

Additional Tests on Strip andSheet:

• Ductility tests• Shear tests/weld seam tests• Creep tests• Fatigue tests• High-speed tests• Charpy impact tests• Automated testing

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3.3 Thin Sheets

Thin sheets and foils are the laststep in the production of flatproducts. Thin sheets are between0.35 and 3.0 mm thick, whereasfoils are typically less than 60 µm.Applications for these flat productsare many and varied and the rangeof tests is correspondingly wide. Onlya few are mentioned in thisbrochure.

Tensile Tests with r- and n-ValueDetermination

Thin sheets are frequently requiredto have good ductility and highstrength. r- and n-values are oftenalso determined via tensile tests inorder to characterize formingproperties; the n-value describes thework hardening – increase in stress –during plastic deformation up to uni-form elongation, while the r-valuedescribes the vertical anisotropy. Then-value is determined from thetensile stress data and strain values;for the r-value the transverse strainon the tensile specimen ismeasured. Tensile specimens aretaken from the strip or sheet at setangles to the rolling direction.

One of the major factors affectingthe r-value is the rolling direction.The sheet thickness is retained asspecimen thickness, while the paral-lel length is produced by milling orpunching followed by finishing; forfoils, strips are cut. Zwick offersvarious machines and devices forspecimen production from differentsheet thicknesses; requirements forstandard-compliant milled specimenedges are well catered-for viacollaboration with our specialistpartners.

Zwick supplies a wide range ofstandard testing systems fordetermining material properties fromtensile tests, starting with table-top

testing machines with 2.5 kNcapacity. Our range of axial andtransverse strain extensometerssimplifies finding the right combinationfor the customer’s requirements andtesting conditions, for inherentlystable sheet a laserXtens laserspeckle extensometer combinedwith a video-optical transverse strainextensometer. This combination isintegrated in a single housing,forming a unified system, and offershigh robustness, excellent measuringaccuracy and simple handling. Theoperator benefits from easier speci-men changing as there are nolonger any contact elements nearthe specimen.

Fig. 1: Tensile test on thin sheet with videoXtens (here with transverse strain measurement option)

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Ductility Tests

Good ductility tests are in great de-mand for thin sheet. Typical formingprocedures such as deep drawingand stretch forming are charac-terized or investigated in standardizedtest methods, for which Zwick sup-plies Type BUP testing machines,with drawing forces up to 1000 kN.An important but complex test is thedetermination of the forming limitcurve, from which designers canderive limit strains which should notbe exceeded during forming pro-cesses. The optical measurementtechnology required for recordingstrains during the drawing process isproduced in collaboration withZwick’s specialist partners.

Fig. 1: Erichsen cupping tools Fig. 4: Resulting test sheet after FLC test(Nakajima)

Fig. 3: Test result from Erichsen Test

Fig. 2: BUP 1000 sheet metal testing machine

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Draw-bead Test on Steel Sheets

This test is designed to determinethe coefficients of friction betweensteel sheet and cup deep drawingtool. The ideal lubricant for the deepdrawing process can then beestablished, enabling cracks andcreases to be avoided and optimizingthe forming process. The draw-beadunit can easily be installed in astandard testing machine. For thetest a sheet metal strip with typicaldimensions 300 mm x 30 mm x 2 mmis gripped axially in the upper speci-men grips and the draw-bead toolclosed; the sheet metal strip is thenpulled through the draw-bead tool.This procedure can be repeatedautomatically, the number of repeatsbeing varied as required. Digital con-trol of the draw-bead tool clampingforce guarantees reliable, reproduc-ible measured values, while the tooldie can quickly be changed to coverdifferent testing specifications.

High-speed Test

Material behavior at high strain ratesis critical for applications in theautomobile industry. Road trafficaccidents involve high materialdeformation speeds, which must betaken into account in automobiledesign. The necessary materialproperties are determined by Zwickusing high-speed testing machinesfrom the HTM series. These servo-hydraulic testing machines achieve20 m/s on specimens at loads up to100 kN.

Fig. 1: Z050 materials testing machine with draw-bead tool

Fig. 2: Metal specimen in high-speedtesting machine

Additional Tests for Thin Sheet

• Flexure and compression tests• Hardness tests• Shear tests/weld seam tests• Automated testing

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3.4 Bars and Rods

Bars and rods are long products withcross-sections up to 240 x 320 mm2

with a wide variety of uses in rollingand forging: for use in wire rod andsections or for automotive forgingssuch as connecting rods and steelrails; generator and turbine shafts inenergy technology; as end productsin bridge building and shipbuilding orin equipment manufacturing andstorage tank construction. Thedemands on their mechanicalcharacteristics are as varied as theirapplications: from high tensile forstructural materials to ductile forsubsequent forming processes.

Tensile Test

Specimens are taken from theproduct and prepared for the tensiletest in accordance with productstandards. Sections of products canbe used directly as specimens fortesting if the cross-section of theproduct permits; the required loadscan exceed 2500 kN, customizedZwick systems up to 5000 kN areoperating successfully. This places

particular demands on specimengrips and clamping, and Zwickdevelops specimen grips backed bynew technologies to ensure thatspecimens do not fail early due tothe effects of clamping.

• Wide range of specimen grips upto 2500 kN

• Wide range of clamping inserts• Wide choice of surface structure

types for inserts• Wide choice of surface finish

types.

Hardness Test

The methods used include micro-hardness for characterization ofmicrostructures, Rockwell tests andhigh-load Brinell test HBW10/3000.Because the hardness test is easy,quick and reliable it is frequentlyperformed and correlated with othercharacteristics. With long productsthe hardenability of the material isoften determined by establishing thehardness distribution along a rod

following a tempering and quenchingtest (Jominy test). Zwick’s productrange contains testing machines forall required hardness testingmethods and includes automatedJominy testers.

• Hardness testing machines for allstandardized hardness testingmethods

• All test load levels which are rele-vant in practice

• Instrumented indentation test upto 2500 N

• Automated and portable hardnesstesting instruments

Fig. 1: laserXtens extensometer with videoXtens option for transverse strain

Fig. 2: Jominy test on single specimen

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Fatigue Test

The areas in which products areused in transport and energytechnology place particular demandson the safety of the products and ofcomponents made from them. Ma-terial properties for fatigue strengthand fatigue limit as determined infatigue tests often have a safety-relevant significance in the choice ofmaterial and design of parts. Speci-mens are tested under cyclic loadconditions and under through-zeroloading. Zwick can supply as stan-dard fatigue testing machines up to600 kN, depending on drive method.The largest servo-hydraulic testingmachine currently in use handlesloads up to 5000 kN.

• Robust servo-hydraulic testingsystems, proven over many years’service

• Robust units with electromagneticresonance drive

• Specimen clamping for all relevanttests

• Controller developed and built/programmed at Zwick

Fig. 2: Torsion testing device for Vibrophore

Fig. 3: Operating principle of torsion testingdevice

Fig. 1: Fatigue test on round specimens

Fatigue Under TorsionalOscillation

The behavior of round productsunder torsion is of interest. For statictesting Zwick supplies drives whichwhen used in combination withmaterials testing machines can applytorque to the specimen and deter-mine the corresponding materialproperties. It is also possible tosuperimpose several load axes andtest the material according to itsuse. For fatigue testing under hightorque alternating load, frequenciesup to over 200 Hz can be achievedin a Vibrophore (HFP) equipped withspecial test fixtures. Using reso-nance conditions means that thetest is both quick and, due to lowpower consumption, cost-effective.

• Customized device construction• Quick test• High energy efficiency• Very low maintenance requirement

Additional Tests for Rods andBars:

• Tensile tests at elevatedtemperature

• Creep tests• Flexure and compression tests• Rotating bar bending fatigue tests• Charpy impact tests• Fracture mechanics tests

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3.5 Sections andReinforcing Steel

Sections of various materials arerolled or drawn out of semi-finishedproducts such as billets or bars; inmany cases they are also weldedfrom bar material. They are used in avast number of applications, re-quiring a wide variety of mechanicaltests. Together with the reinforcingsteel and ribbed reinforcement barsso vital to civil engineering they forma group of important structuralmaterials which – in the case ofconcrete-reinforcing steel – aresubject to regulatory control.

Tensile Test

Because concrete has high com-pressive strength but lower tensilestrength, it is reinforced by steelembedded in it. Reinforcing steelsare mainly produced in diametersfrom approx. 5 mm to approx.60 mm. The smaller diameters arethen further processed into mats orlattices before having concretepoured over them on site. Testingthese ribbed steels poses a par-ticular challenge because apart fromcutting to length, no further me-chanical specimen preparation takesplace.

The on-specimen strain measure-ment required for precise determina-tion of the yield point is predomi-nantly performed using the Macroextensometer, which records thestrain up to break reliably with nodetrimental effects to itself.

The Macro extensometer has thefollowing features:• High robustness for measurements

up specimen failure• Swivelling knife-edge on

sensor-arm tip• Automatic attachment and

removal of sensor arms to/fromspecimen

• Large diameter range• Fully integrated into automatic test

sequence• No manual operation necessary• Optional automatic withdrawal

from specimen area

Flexure Test

Flexure tests on reinforcing steel areused to test ductility. The specimenmust not lose strength and nocracks must be detected on visualinspection. Various die radii andanvils are specified, depending onthe standard, the bending angle as arule being 90° or 180°. For this testZwick has hydraulic testing machinesand flexure test kits according to thestandards. If required two test areascan be installed on electro-mechani-cal testing machines and used forflexure and tensile tests, eliminatingthe need to change machine set-upor configuration.

• Plug-in system for easy adaptationof flexure test kit

• Flexure test kits are standard-compliant

• Use of two test areas in onetesting machine

Fig 1: Tensile test on rebar and macroextensometer

Fig 2: Flexure test kit for rebars

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Shear Test

The weld points of reinforcing matsand lattices are tested for shearing.This involves removing specimensfrom welded mats and lattices andplacing them in special close-fittingspecimen grips. Specimen gripsused for this type of test must beaccurately matched to the diameterand position of the ribbed wires inorder not to influence the shearingloads. Zwick has many decades ofexperience in this area and hasdeveloped a comprehensive range ofaccessories.

Automation of ReinforcementSteel Testing

Reinforcing steel is produced in largeamounts and must be continuallytested for production control. Zwickhas developed automated systemsin which specimens, cut to lengthfrom rod material or separated frommats and lattices, are loadedmanually into magazines, after whichthey are tested completely auto-matically. Artificial ageing at 100 °Ccan also be integrated into this typeof testing system. Cross-sectionsare measured in accordance with

Fig. 1: Welded seam test T-joint

Fig. 2: Shear test on lattice rod

Fig. 3: Detail of testing device

Fig. 4: Robotic testing system for testing reinforcing steel

Fig. 5: Automatic length measurement Fig. 6: Automatic rib measurement

standards and with high accuracyand specimens can be optionallysorted according to test result forlater visual inspection.

• Customized total solutions• Integration of all relevant tests• High availability• Useful options for forwarding fault

reports

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Cyclic Test

Earthquake protection requirementsfor high-rise structures mean thatreinforcing steels for certain countriesmust be subjected to specific tests.Standard-compliant cyclic tensile-compression tests (carried out onribbed steel rods cut to length)depart significantly from the elasticrange of the specimen. Grip-to-gripseparation, stroke and frequency arespecified by the standard accordingto the specimen diameter. After thetest the deformed specimen isexamined visually for cracks. Thepower and short-term energyneeded for these tests is consider-able. Zwick has developed a servo-hydraulic testing machine withhydraulic accumulator for this test,enabling loads of over 1200 kN to beapplied with strokes of more than20 mm at over 1 Hz.

• Earthquake tests to standard• Hydraulic, parallel-closing

specimen grips for compressionand tensile loading

Fatigue Test

Reinforcing steels are required bystandard to have a defined fatiguestrength, which must be verified.These fatigue tests are most quicklyand economically performed usingresonance pulsators. Zwick’sVibrophores (HFP) offer an optimumsolution for this application up to600 kN. Specimens can have adiameter up to 36 mm; from 14 mmthey must be grouted – a groutingdevice is available.

Fig 1: High capacity machine for eartquake tests on rebars

Fig 2: Rebar specimen grips

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3.6 Wire and Cable

All metals can be formed into wire,which is a very common metalproduct form. Wires are used in allareas of the manufacturing industry:in construction engineering, inelectrical technology and energytechnology, in aircraft and automobi-le manufacture and in medicaltechnology. Wire braided into cablesis used in load-bearing applications incableways, lifts and cranes, inbridge-building, anchorings andfastenings and in many other areas.The wide range of applicationsplaces extremely varied mechanicaldemands, with the result that testingmaterial properties is often highlysafety-relevant.

Tensile Test on Wire

Tensile tests on wire represent achallenge for specimen grip design.Wires can be very thin and at thesame time very strong; as theycannot be machined for testing,cut-off lengths are used and requiresuitable gripping arrangements –simply clamping wires between jawscan cause failure at an unwantedlocation. Zwick can supply specimengrips featuring various gripping tech-nologies, providing safe, reliabletesting. For strain measurement theoptical extensometer videoXtens canbe used with thin wires, with thickerwires optical or contact extenso-meters can be employed.

• Wide range of specimen grips forsingle wires

• The right extensometer for everyapplication

Fig. 1: Tensile test on fine wire with macroextensometer

Fig. 2: Clamping device for tension wire

Tensile Test on BraidedTension Wire

With braided wires several wires arewound together; under tensileloading they try to unwind. Zwick’sspecial clamping technology avoidspremature failure at an unwantedlocation. Failure of these braidedwires generally involves individualfraying wires with high whiplash, andwith a strong probability of damageto contact extensometers; ouradvice is to use optical extenso-meters.

Optical extensometers:• Long measurement travel

(up to 900 mm)• High resolution of 5 µm over whole

measurement travel

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Tensile Test on Wire Ropes

High strain levels have to be takeninto account during tensile tests onwire ropes, as do high loads, bothresulting in torn individual wireswhipping back with high energy onfailure. Safety precautions must betaken to eliminate risks from thetest.

Rotating Bar Bending FatigueTest

In many applications, wires aresubjected to various cyclic stresses.Fatigue strength can be determinedquickly and easily in rotating barbending fatigue tests, in which therapidly rotating (up to 6000 rpm)specimen is additionally loaded witha force perpendicular to the axis ofrotation. This flexure plus the rotationprovides a tensile-compressionloading of the specimen surface.Specimen preparation is especiallyimportant here, an undamagedsurface being essential. Fig. 1: Horizontal testing machine for wire ropes

Fig. 2: Rotating bend fatigue test system (UBM)

Additional Test Applications forWire and Cable:

• Torsion tests• Hardness tests• Fatigue tests

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3.7 Pipes

Pipes transport granulated materials,liquids and gases; these can be ag-gressive or neutral.

Pipes are used in widely differingsurroundings, including nuclear po-wer stations, in and above theground for transporting oil and natu-ral gas, in engines for fuel deliveryand exhaust gases and in thechemical industry for creating rawmaterials. This causes them to beproduced in a wide range ofmaterials and alloys, using variousproduction processes, in anapparently endless variety of forms.

Fig. 2: High capacity machine with double actuator hydraulic specimen grips

Tensile Test

Ways of testing tensile specimenstaken from or consisting of pipesvary according to the product form.Small, thin pipes are crushed at theends for a sufficient length and thenpulled, while cores are used in largerdiameter pipes to prevent pre-damage through crushing. Withlarger pipes standardized specimensare produced from material removedfrom the wall of the pipe. It ispossible that specimens (takenlongitudinally) may display the curveof the pipe radius; for reliable, pre-damage-free testing this radiusshould be compensated for withsuitably shaped counterpieces.Zwick supplies tensile testingmachines from 500 N to 2500 kN,with appropriate specimen grips.

Fig. 3: Tensile test on pipe wall specimen

Fig. 1: Pipe wall specimen

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Fig. 1: Compression test

Fig. 2: DWT high-energy drop-weight tester

Compression Tests

Crush tests are carried out on pipesto test their strength and ductility.These characteristics can be ofconsiderable significance in situationswhere the safety of pipework mustnot be affected by earthquakes,especially when pipes are laiddirectly in the ground. The test areasof the Zwick materials testingmachine can be set up inaccordance with pipe diameters tomake handling of specimens bothsimple and time-saving.

Drop-weight Test

For large oil and gas mains,specimens from the pipe wall aresubjected to a drop-weight test toAPI 5L. Specimens with the heightof the original wall thickness andwidths of several centimeters aresubjected to abrupt loading via avertically falling weight with a tup.The energy (weight and releaseheight) is set so that the specimenbreaks, allowing the fracture surfaceto be assessed visually. Zwicksupplies drop-weight testers up to100,000 J for this type of test.

Additional Test Applications forPipes:

• Tensile tests at elevatedtemperature

• Creep tests• Hardness tests• Weld seam tests• Fatigue tests• Charpy impact tests

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3.8 Castings and Forgings

Castings and forgings are predomi-nantly used in the automobileindustry and for aircraft manufacture,as well as power-station construc-tion. Casting technology allowscomplex parts to be manufacturedcost-effectively, with an ever-increasing use of light metal castingsto reduce weight, especially inengine manufacture. Forged com-ponents are used to meet severedemands on strength, or extremesof pressure and impact loading, aswith crankshafts and connectingrods in engines, or generator andturbine shafts in power stations.

Fatigue Test

In practice, where castings andforgings are concerned, everythingdepends on reliable estimation offatigue strength. This requiresspecimens and, importantly, entirecomponents such as connectingrods to be tested intensively undercyclic loadings. Operating conditionsare reproduced, in resonance testingmachines for example, and com-ponents stressed with cyclic loadsup to 600 kN at frequencies up to300 Hz. Zwick’s range of highlyefficient, cost-effective resonancetesting machines is now backed bya greatly expanded servo-hydraulictesting machine range.

Fig. 1: Tensile test on round specimen

Fig. 2: Fatigue test on connecting rod in oilbath

Tensile Test

Cast and forged components areproduced so as to require theminimum of further processing tomake them fit for their intendedpurpose. For tensile tests this meanseither removing specimens fromspecified locations or using thecomponent as a whole to determinetensile strength. Testing the wholecomponent requires high test loadsand component-specific grippingarrangements and fastenings, whilecomponent geometries often resultin the production of specimens withsmall final dimensions. For small

Fig. 3: Brinell indentation test with ringlightoption

round specimens Zwick providesspecial specimen grips which areeasy to handle and allow the use ofautomatic extensometers; completecomponents are catered for by acomprehensive accessory andoption package.

Hardness Test

The hardness value is an importantcharacteristic during monitoring ofthe manufacturing process for castand forged components. The high-load Brinell method is often used oncomponents, the large indentationsenabling a stable average value forthe metallographic constituents tobe obtained. The hardness of metal-lographic constituents is determinedon specimens via Vickers micro-hardness testing. Zwick’s operator-friendly Brinell hardness testingmachines with automatic indentationmeasurement up to load stage 3000(29,000 N) are complemented by acomprehensive micro Vickersinstrument range, including fullyautomatic systems.

Further Testing Applications forCast and Forged Components:

• Tensile tests under temperature• Torsion tests• Rotating bar bending fatigue tests• Charpy impact tests.

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3.9 Fasteners

First and foremost amongstfasteners are nuts and bolts in alltheir many variations; screws, rivetsand hooks and eyes are also usedto join parts which must not separa-te under load. Fastener technologyin general, particularly welding andassociated technologies, isconsidered here.

Tensile Test

Bolts and screws are selected verycarefully as components for industrialapplications and integrated preciselyinto the design. Accuratedetermination (via tensile tests) of theelastic tensile modulus and the limitsof elastic loading is essential, as fromthis the limit forces for a secure,reliable screwed fastening areestablished. The huge number ofapplications requires a vast range ofscrews and bolts of many differenttypes. Zwick’s comprehensiveselection of specimen grips, with theoption of customized solutions,simplifies testing in this area.

Fig. 1: Shear test on riveted joint

Fig. 2: Screw specimen grips for screwsand round specimens

Shear Test

In addition to single-axis tensileloading, shear loads also occur inthis application and can quicklycause a joint to part. Shear tests onjoined parts or specimens aretherefore essential, particularlywhere riveted joints are involved.Accurate load application is essentialto prevent other forces arising inaddition to the shear force anddistorting results. Zwick works withthe customer to develop aspecification for the correct grippingof the specimen or components andthen produces the requiredarrangement. These testing devicescan be simple or very complex, butalways fulfill their requirements.

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Fatigue Test on Screws/Bolts

In addition to static loading, fastenersare generally subjected to frequentcyclic loadings, including vibrations.Fatigue tests on screws and bolts(and other items) are most quicklyand efficiently performed in aVibrophore, which can apply cyclicloads up to 600 kN in a frequencyrange up to approx. 300 Hz, usinggrips tailor-made for screws/boltsand other fasteners. The magneticdrive which generates controlledresonance in the system (and in thespecimen) requires minimal power,resulting in highly cost-effectivetesting.

Fatigue Test on H-shapedSpecimens

In H-shaped specimens the individualjoints are subjected to commoncyclic loading in tension and com-pression and the fasteners to a sheareffect. H-specimen grips designedfor this test initially distribute theforces over the entire structure. Thebending-up and resultant looseningof the structure can be measuredwith an extensometer. With thestrain values the testing machine –in this case also a Vibrophore – canprovide control of loads or strain,depending on how the test isconducted.

Fig. 2: Bolts/screws after break

Fig. 1: Fatigue test on bolts/screws

Fig. 3: Fatigue test on H-specimens

Fig. 4: H-specimens before test

Additional Testing Applicationson Fasteners

• Creep tests• Flexure and compression tests• Torsion tests• Hardness tests• Drop-weight tests

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4 Quasi-Static MaterialsTesting: Products andServices

4.1 Materials TestingMachines

Applications

Materials testing machines are usedto determine the strength anddeformation behavior of specimensand components, mostly undertensile, compression and flexureloading. Shear and torsion loads arealso used. These testing machinesfeature long travel, wide test-speedranges and interchangeable sensorsand tools, allowing testing of speci-mens and components with widelydiffering forms and dimensions,made from various materials andmaterials combinations and with cor-respondingly different characteristics.

Basic Concept

Zwick has three series of quasi-static materials testing machines,differing in design, equipment,performance characteristics andexpandability. This allows us toprovide the most suitable machinefor every budget.

• The zwicki-Line consists of high-quality, compact machines. Theseportable, easy-to-use single-column load-frames have beenspecially designed for mechanicaltesting with low test loads of 0.5 to5 kN.

• The ProLine was developed tosatisfy the demand for cost-effective testing machines forfunction- testing components andstandard tests on materials. The‘Pure Portfolio’ accessory rangefor the ProLine ensures an attrac-tively priced system and shortdelivery times. Test loads are from5 kN to 100 kN.

• The Allround-Line provides thesolution to challenging testingsituations and fulfils the mostexacting requirements. It can beequipped or upgraded via acomprehensive accessory rangeand used with special sensors andmulti-channel measuringtechnology.

Load Frames

Our standard production load framesare rated for loads up to 2000 kN.We design and manufacture specialversions for specific applications, e.g.for higher rated loads or horizontallyaligned load frames for testing in thecomponent installation position.

zwicki-Line Single-ColumnModel

This load frame is based on a highlybend-resistant aluminum extrusion,which was developed especially forthe zwicki-Line. The workspace isfreely accessible from threedirections, making the zwicki-Linealso suitable for small componenttesting and for use as a hardnesstester. This modular system’s lowweight and compact base make iteasily portable – and it will fit on anylaboratory table.

Fig 2: ProLine Z050TN with CE conforming protective screen

Fig 1: The zwicki line is available in threedifferent heights

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Fig 2: Allround-Line floor-standing machine Z600Fig 1: Allround-Line floor-standing machineZ100

ProLine Single and Double-Column Table-Top Machines

ProLine load frames incorporate tworound steel columns, providingprecise crosshead guidance, whilethe integrated spindle and guideprotection guarantee reliable opera-tion in industrial applications or whentesting splintering materials.

Allround-Line Table-Top andFloor-Standing TestingMachines

The table-top testing machines areequipped with two columns made ofpatented extruded aluminum. Theyare light and highly bend-resistantand combine the functions of spindleguide and spindle protection. T-slotson the outer sides allow simplemounting of accessories such asfixtures or safety guards, unrestrictedby the moving crosshead.

All table-top testing machines canbe fitted with stands to bring theworkspace to the optimum heightfor the application or operator. Thisallows, for example, comfortableseated operation with plenty of leg-room, making the system well suitedto wheelchair users also.

Hard-chrome plated guide columnsand a precision ball screw with play-

free spindle nuts guarantee a highlevel of precision for the floor-standingmachines. Various crosshead con-figurations are available, providingeither an upper or lower test area –or both. All load frames with electro-mechanical drives can optionally beequipped with a second test area.Benefits include rapid change to adifferent type of test without havingto reconfigure the entire machine.

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Drives for Quasi-StaticTest Situations

Electromechanical Drives

All electromechanical drives incorpo-rate play-free, low-wear ball screwsand digitally controlled drives and areused with load frames rated for testloads up to 2000 kN. Combined withthe digital measurement and controlsystem, they offer the followingadvantages:• extremely wide, infinitely variable

speed-range• very low speed-settings possible

(from about 0.5 µm/min)• highly precise, exactly reproducible

positioning and speeds.

The ProLine and zwickiLine testingmachines are fitted with DC motors.All other testing machines haveespecially low-inertia brushlessthree-phase AC motors.

Hydraulic Drives

This drive is located centrally to thefixed crosshead, making the testarea below easily accessible. A servoor proportional valve regulates the oilflow between the hydraulic unit anddifferential cylinder. The oil pad in theupper pressure chamber eliminatesthe familiar problem of plunger pistons“jumping” when a specimen breaks.For high test loads in particular, thehydraulic drive is an extremely cost-effective solution.

Hybrid Drives

These patented drives combine theadvantages of the electromechanicaldrive (high precision) with those ofthe hydraulic drive (high forces). As aresult, even long-stroke cylindersdesigned for very high loads can bemoved and positioned very precisely.

This approach allows two parallelmounted trough-rod cylinderscoupled to the moving crosshead tobe traversed with precise synchro-nism and regardless of their respec-tive loadings. They follow, accuratelyand virtually without hesitation, theposition parameters set by anelectromechanical pilot drive. Specialfeatures of this drive:• long travel range (no adjustment of

fixed crosshead necessary• relatively low load-frame height

ProLine Load Frames and DrivesModel Z005 Z010 Z020 Z030 Z0501) Z100• Max. test load [kN] 5 10 20 30 50 100• Test area height [mm] 1070 1050 1050 1370 1370 1360• Test area width [mm] 440 440 440 440 440 640• Test area depth [mm] 4 4 4 4 4 4• Max. crosshead-speed [mm/min] 500 1000 500 300 180/600 300• Crosshead travel resolution [µm] 0.039 0.038 0.018 0.012 0.007/0.016 0.008• Max. power consumption [kVA] 0.8 0.8 0.8 0.8 0.8/2.6 31) This testing machine is available in two electronics variations.

zwicki-Line Load Frames and DrivesModel Z0.5 Z1.0 Z2.5 Z5.0• Max. test load [kN] 0.5 1.0 2.5 5.0• Test area height

* Shortened [mm] 570 570 573 -* Normal [mm] 1070 1070 1073 1030* Raised [mm] 1370 1373 1373 -

• Test area width [mm] 4 4 4 4• Test area depth [mm] 100 100 100 100• Max. crosshead-

speed [mm/min] 2000/3000 2000 1000 600• Crosshead travel resolution [µm] 0.2453 0.2265 0.0996 0.0399• Max. power consumption [kVA] 0.44 0.44 0.44 0.44

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Model Z005 Z010 Z020 Z030 Z050 Z100 Z150• Max. test load [kN] 5 10 20 30 50 100 150• Test area height

* Normal [mm] 1) 1045/1025 1045/1025 1045/1025 - - - -* Raised [mm] 1) 1445/1425 1445/1425 1445/1425 1355/1325 1355/1325 1355 1535* Extra high [mm] 1) 1795/1785 1795/1785 1795/1785 1755/1725 1755/1725 1755 -

• Test area width* Normal [mm] 440 440 440 440 440 - -* Widened [mm] 640 640 640 640 640 640 640

• Test area depth [mm] 4 4 4 4 4 4 4• Max. crosshead-

speed [mm/min] 3000 2000 1000/20003) 1000 600 750/15003) 900• Crosshead travel resolution [µm] 0.0410 0.0272 0.0136/0.05433) 0.0271 0.0163 0.0207 0.0123• Max. power consumption

[kVA] 2 1.9 2.1/2,63) 2.3 2.3 4/63) 5.5

Allround-Line Load Frames and Drives (Floor-standing testing machines)Model Z050/Z100 Z150/Z250 Z300E Z400E Z600E Z1200E• Max. test load [kN] 50/100 50/250 300 400 600 1200• Teat area hight [mm] 1825/17601) 1715/16551) 1785 1785 1940 2266• Test area width

* Normal [mm] 630 630 630 630 740 800* Widened [mm] 1030 1030 - - -

• Test area depth [mm] 4 4 4 4 4 4• Max. crosshead-

speed [mm/min] 1000/20003) 900/600 250 250 200 400• Crosshead travel resolution [µm] 0.0270 0.0123/0.0082 0.0035 0.0035 0.002 0.0041• Max. power consumption [kVA] 4/53) 5.5/6 7/132) 7/132) 20/262) 20/252)

1) Second dimension applies to version with widened test area 3) Depending on drive selected2) Higher consumption if hydraulic specimen grips used

High Force Load Frames and Drives (Standard range with hydraulic or hybrid drives)Model Z400H Z600H Z1200H Z1600H Z2000H Z600Y Z1200Y Z2000Y• Max. test load [kN] 400 600 1200 1600 2000 600 1200 2000• Test area

* Width [mm] 670 670 850 800 850 790 860 1200* Heigth [mm] 1578 1578 1876 2076 2236 1895 2330 2495* Heigth [mm] with adjustable crosshead 1878 1878 2184 2834 2829 - - -

• Max. travel [stroke, mm] 500 500 600 600 600 850 1000 1000• Crosshead travel resolution [µm] 0.16 0.16 0.16 0.16 0.16 0.05 0.05 0.05• Max. test speed [mm/min] 340 340 200 250 200 250 250 250• No. of support/guide columns 2 2 4 4 4 2 2 2• Max. power consumption [kVA] 8.5 8.5 15 20 20 8.5 15 25

Allround-Line Load Frames and Drives (Table-top testing machines)

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Fig 4: SP testing machine

SP Testing Machine

This materials testing machine isdesigned for testing steel specimens-flat, round or sections. It can per-form tensile tests, together withcompression, flexure and foldingtests, and has an extra-stiff loadframe with a hydraulic central driveon the upper crosshead, which canbe fixed or movable as required.Hydraulically operated wedge gripsare provided as standard and testload measurement is via electronicload cells. For strain measurementthe Macro sensor-arm extensometer

and the Clip-on extensometer areavailable. Despite its size, thismachine requires no specialfoundation, but simply stands onrubber mats placed directly on theconcrete floor.

SP-testing Machines with Hydraulic Drive System for Nominal Loads from 400 to 1500 kNSeries SP400.xx SP600.xx SP1000.xx SP1200.xx SP1500.xx• Max. load [kN] 400 600 1000 1200 1500• Working area:

Height [mm] 1) 100-600 100-600 120-720 120-720 120-720Height [mm] 2) 0-800 0-800 0-900 0-1000 0-1000Width [mm] 670 670 700 850 850

• Max. travel [mm] 500 500 600 600 600• Travel resolution [µm] 5 5 5 5 5• Max. test speed [mm/min] 250 200 200 200 200• No. of columns 2 2 4 4 4• Max. power consumption [kVA] 10 10 18 18 181) with fixed crosshead 2) with adjustable crosshead

Fig 1: High capacity Z1200E Fig 2: High capacity Z2000H Fig 3: High capacity Z2000H

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4.3 Sheet Metal TestingMachines

Applications

Testing ductility of sheets to commoncurrent standards (DIN EN ISO 20482,DIN EN 1669)

Testing the influences of surfacetreatments and lubricants duringtypical forming techniques such ascupping tests and earing tests.Testing the effect of tool andprocedure parameters on theforming process.

Special Features:

• Quick, easy test equipmentchange (e.g. punches, blank-holders etc.) – numerous modularupgrading options available

• Low piston-cylinder friction, provi-ding accurate measurement re-cording and excellent reproducibility

• Hydraulic cup extractor viaintegrated piston, with piston rodacting through drawing punch(BUP 200 upwards)

• Swivelling electronic display unitadjustable to convenient viewingposition – all operating elementsergonomically arranged

• Adjustable automatic blank-holderload-removal during the test allowscup-drawing without earingcrushing (BUP 200 upwards)

• Automatic setting of pre-selectedsheet clamping force after blankingprocedure

• Automatic piston withdrawal andswitch-off after end of test viacrack recognition or on reachingmaximum ram stroke (s-limit)

• Alteration of deep drawing speedduring test possible (BUP 400upwards)

• Hydraulic opening and closing oftool head

• Extremely quiet, clean operation

Sheet Metal Testing Machines (BUP)Series BUP 100 BUP 200 BUP 400 BUP 600 BUP 1000• Max. ram forces [kN] 100 200 400 600 1000• Max. clamping force [kN] 25 25 400 600 1000• Punching force [kN] – 150 400 600 1000• Max. test stoke [mm] 80 80 120 120 150• Max. test speed [mm/min] 750 750 750 750 750• Round blank diameter [mm] 150 150 270 270 270• Max. sheet strip width [mm] 120 120 260 260 260• Max. sheet strip thickness [mm] 6 6.4 10 10 10• Max. round blank diameter [mm] – 118 250 250 250• Max. power consumption [kW] 4 4 12 12 12

Fig 1: Sheet metal testing machine BUP 1000

Fig. 2: Electronic display panel

Fig. 3: BUP 200 with measurement andcontrol electronics for forming-limit curve (FLC)

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Fig. 2: Zwick/ZHU2.5/Z2.5 universalhardness testing machine with hardnessmeasurement head

Fig. 1: Zwick/ZHV30/Z2.5 Vickers hardnesstesting machine with motorized compound-table

4.4 Hardness TestingMachines and Instruments

Zwick/ZHV20/Z2.5 VickersHardness Testing Machine

The ZHV/ zwicki-Line Vickershardness testing machine isproduced by integrating a Zwickhardness testing device used foroptical methods with a testingmachine from the zwicki-Line range.The integrated load cell permitselectro-mechanically applied testloads between 2 and 200 N (ZHV20/Z2.5) or between 3 and 300 N(ZHV30/Z2.5). A high-resolution CCDcamera is mounted on a microscopeangled at 90°. Indentor carrier(s) andlenses are integrated into the turretso that rotating it brings them intothe correct position to make ormeasure the indentationrespectively. The turret is providedwith four carriers in total, allowingvarious lenses to be used with oneindentor.

ZHU/zwicki-Line UniversalHardness Testing Machine

The ZHU/Z2.5 universal hardnesstesting machines are based on thezwicki-Line and can be used for allclassical testing methods, includingRockwell, Vickers, Knoop, Brinelland ball indentation hardness. Theyare also suitable for the innovativeinstrumented indentation test usedto determine hardness plus additio-nal metallic materials parameters(referred to as Martens hardness,EN ISO 14577).

The ZHU/Z2.5 features a patentedhardness measuring head (resolution0.02 µm) with integrated digitaldepth and force measuring system,mounted in a zwicki-Line materialstesting machine with modified drive.Add to this state-of-the-arttestControl measurement and controlelectronics and Zwick’s intelligenttesting software and the result is awell-balanced, high-precisionmeasuring system.

The ZHU/zwicki-Line is available withtwo different test areas: 350 mm or850 mm. To enable high-precisionmeasurements in the variousapplication areas, two hardnessmeasuring heads with exchangeableindentors and sensor foot are

available: 2 … 200 N or 5 … 2.5 kN.This innovative testing system hasthe additional benefit of testXpert® in-telligent software, which has provedhighly effective in standard situationssuch as quality assurance and alsooffers an excellent range of optionsin demanding areas such asresearch and development.

The ZHU/zwicki-Line range iscomplemented by a comprehensive,standardized range of accessories,including a selection of indentors,hardness comparison platens,clamping systems and compoundtables with manual or fully automaticcontrol.

Sample features:• Multiple curve for direct comparison

of tests in a series• Configuration of user-specific test

sequences: special test sequencescan also easily be defined andexecuted

• Suitable for production-line testing

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Fig. 2: Turret capable of holding four indentors and two lenses – Zwick/ZHU250 topLine withtestXpert® II connection

Fig. 1: Universal hardness testing machine

Fig. 3: Dark field illumination with ringlightoption

Zwick/ZHU topLine UniversalHardness Testing Machine (upto 30,000 N test load)

Today’s state-of-the-art universaltesting machines use innovativeelectromechanical technology forhigh-precision testing in a widerange of applications, particularly forquality assurance, production-linetesting and in the laboratory.

Zwick’s three ZHU topLine hardnesstesting machines – ZHU250top (1 -250 kgf / 9.8 - 2452.5 N), ZHU750top(3 - 750 kgf / 29.4 - 7357.5 N) andZHU3000top (20 - 3000 kgf / 196.2 -29,430 N) are based on innovativeoptical zoom technology, eliminatingthe need for frequent lens changes.The closed loop/load cell load appli-cation technology provides solutionsfor both optical and depth measure-ment testing in accordance withrecognized testing methods.

Ringlight OptionA further option available is a ringlightusing LED technology. This usesdark field illumination to produce aspecial contrast image which allowsmore precise, automatic indentationmeasurement, particularly with softermaterials (e.g. < 200 HB), unaffect-ed by loss of clarity due to edgebulging.

Revolver OptionOne very special feature is the ‘Re-volver’ motorized turret optionallyavailable with the ZHU250 top andZHU750 top. This can hold 4 diffe-rent indentors and 2 lenses (x2.5 /x4 / x10 / x20). Add to this a motor-ized lead screw (in place of ahandwheel) and the result is a top-of-the-range hardness tester with acomprehensive range of accessoriesavailable to suit any application.

Intelligent Testing withtestXpert® II (Option)An integrated RS232 interface allowstransfer of test data to Zwick’stestXpert® II testing software forevaluation, ready for straightforwarddocumentation or connection toquality assurance systems.

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Fig. 2: Zwick/ZHV30 manual low-loadVickers hardness tester

Fig. 1: Zwick/ZHV1 micro Vickers hardness test with motorized compound-table and testXpert®

Zwick/ZHV1 and ZHV2 MicroVickers Hardness Testers

Zwick’s micro Vickers hardnesstesters are available in two versionsto suit different load ranges: ZHV1with weights from 10 to 1000 gfand ZHV2 with weights from 25 to2000 gf. They can be used for testingin compliance with the followingstandards:

• Vickers (HV) to DIN EN ISO6507,ASTM E 92 and

• Knoop (HK) to DIN EN ISO 454,ASTM E 384.

The same operating concepts areavailable for both ranges:ZHV-m (manual) – measuring isperformed manually by the operator,using a microscope. The automaticturret allows one-button controlwhen changing between indentorand lenses.

ZHV-PC – the ZHV1-m and ZHV2-m can be retrofitted with a CCDcamera for optical evaluation using aPC system.ZHV-s (semi-automatic)/ZHV-a (fullyautomatic) – both feature fully auto-matic operation to the operator’sspecifications. The semi-automaticversion differs in having manualindentation focusing against motor-ized auto-focusing. Motorized load-change, automatic indentationmeasuring, automatically controlledturret via testXpert® for changingbetween indentor and lens positionsplus control of motorized compoundtable and fully automatic testsequences.

Zwick/ZHV30 Low-LoadVickers Hardness Tester

The Zwick/ZHV30 manual Vickershardness tester covers Vickers (HV)applications DIN EN ISO 6507 andASTM E 92. With a load range of 0.2to 30 kgf the ZHV30 can alsooptionally be equipped for Knoop(HK): DIN EN ISO 4545, ASTM E384 and Brinell (HB): DIN EN ISO6506, ASTM E 10. As with theZwick micro Vickers hardness tester,measurement with the Zwick/ZHV30is performed manually by theoperator, using a microscope. Theautomatic turret allows one-buttonoperation when changing betweenindentor and lenses, while operatorinfluence during hold time iseliminated by the fully automatic testsequence to a specified time frame.

A CCD camera cam retrofitted tothe ZHV30 to enable optical evalu-ation via a PC system. Opticalmeasurement of the indentation isthen performed either manually orautomatically with testXpert®

connection.

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Fig. 2: Zwick MIC 10 portable hardness tester

Fig. 1: Zwick/ZHR 8150SK for series testswith small batch sizes

Fig. 3: Zwick Webster hardness testing pliers

Fig. 4: Zwick PZ3 Brinell testing clamp fortests up to 3000 kgf

Zwick/ZHR Rockwell HardnessTesting Instruments

The various instruments in thisproduct range are designed for:• Classical Rockwell method

(load: 60 - 150 kgf)• Super Rockwell method

(load: 15 - 45 kgf)• Combination of these methods

(load: 15 - 150 kgf)

A special feature of these instru-ments is a patented indentor holderfor hardness testing in hard-to-access locations. Straightforwardoperating is ensured by:• Automatic operation• Load-weight selection via rotary

knob or touch-screen• Automatic load application and

removal• Automatic evaluation, including

conversion.

Portable Zwick Hardness Testers

Portable hardness testing methodsare used in a variety of ways and areattracting increasing interest for useon large or non-transportable com-ponents and plant for which sta-tionary, laboratory-based testers areunsuitable. Zwick has a compre-hensive range of portable hardnesstesting equipment for a wide rangeof applications.

Zwick MIC10 Hardness Tester(UCI method)The Zwick MIC 10 allows quick, handy,on-site hardness testing in conformitywith the UCI (Ultrasonic ContactImpedance, standardized to ASTM A1038) method. In what is known asthe comparative method, the inden-tation made by the diamond in thesurface of the material is measuredelectronically and the hardness valueis shown immediately in the display.

Zwick DynaPocket – DigitalRebound Hardness TesterThe Zwick DynaPocket is anextremely handy integrated digitalhardness testing instrument whichuses the dynamic rebound method(Leeb) (standardized to ASTM A956).Its compact design allows easy on-the-spot testing of bulky, non-trans-portable components such asforgings or castings – even atlocations which would be difficult forother testers to reach.

Zwick Webster HardnessTesting PliersPortable, easy-to-use testing plierswith built-in indentor and spring.Squeezing the grips togetherpresses the indentor (via the spring)into the specimen (material thick-ness 0.6 - 8 mm) and theindentation depth is shown on thescale. The value is read off andconverted to Rockwell hardnessusing the chart supplied. Thesetesting pliers are used for aluminium,aluminium alloys, brass, copperalloys and steel in the rangeRockwell E 20 to E 110 (max.).

Zwick PZ3 Brinell TestingClampThis unique portable hardness testeris suitable for standardized staticBrinell ball indentation tests up to3000 kgf (29,420 N). Hardness testscan be performed on materials andworkpieces unsuitable for testing inthe laboratory. Examples of theseinclude stored steel stocks, finishedstructures, machines and largermetal components.

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4.5 Measurement andControl Electronics

The measurement and controlelectronic is an essential element ofany testing machine. Its design andscope determine which drive systemit regulates, which measurementsystem it is connected to, and whichfunctions can be controlled with it.

Zwick testing machines usetestControl electronics. Developedby Zwick in-house, testControlfeatures state-of-the-art technologyand the highest possible qualitystandards, providing maximumperformance and long-term invest-ment security.

Special features include:

• Synchronized test data recordingof all measuring channels with highresolution and measurementfrequency

• 500 Hz real-time processing oftest data for monitoring and event-oriented control of the test se-quence (e.g. speed change uponreaching offset yield or proof stresslimit) and safety limits

• Adaptive control for exactly repro-ducible test speeds and positions

• Modular design enables testControlto accommodate customers’ indi-vidual requirements – if thesechange over time, testControl canbe adapted to suit (e.g. additionalload or strain channels or externalinput / output channels)

• Direct, synchronous correction intestControl for testing systemelasticity, providing high positioningaccuracy, including under load.

Fig. 3: Terminal box for multiple signals

In the base model, testControl andthe testing machine are operated viaa PC and testXpert® software,making the system easy to expandand configure to suit the most variedapplications – and at the same timeextremely flexible and convenient inoperation.

As an alternative to PC operation, anoptional stand-alone variation offerssimple, direct operation via a colordisplay, a key pad and a few intuitivefunction keys. A printer can beconnected directly to output testresults.

This system can also be connectedto a PC, thus providing access tothe benefits of testXpert® software.Housed in a compact casingmounted directly on the load frame,the electronics ensure high overallavailability and reliability of the testingsystem.

Fig. 1: testControl electronics Fig. 2: Optional I/O module with terminalbox for synchronous input and output ofexternal signals

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4.6 testXpert® II – Intelligentand Reliable, the NewSoftware Generation forMaterials Testing

With testXpert®, Zwick Roell has setthe standard for intelligent materialstesting software. Unlike othersoftware, Zwick has standardizedtestXpert® for all of its applications,no matter whether static or dynamictests – so you spend less timelearning to handle software andmore time conducting tests. WithtestXpert® II, you benefit from over80 years of testing experience andfrom over 15,000 successfulinstallations worldwide.

Some Significant Benefits oftestXpert® II

Ingeniously SimpletestXpert® II is organized so that youcan operate it intuitively. Expressivesymbols and a clear menu structureenable users quickly to becomeoriented and reduce the familiariza-tion period dramatically. The menubar is set up according to the needsof the user, making working withtestXpert® II ingeniously simple.

IntelligentWizards help you to set up orchange test procedures and testreports. Should you have anyquestions, our extensive context-sensitive online help feature willquickly deliver the answer.

Modular DesigntestXpert® II gives you a softwaresystem tailored to your needs.testXpert® II’s modular design makesthis possible – you only buy whatyou need. Upgrading your existingsystem with additional test programsor options is – of course – noproblem.

Compatible with your HardwareZwick testXpert® II is compatible withall commercially available PCs andlaptops without the need for an addi-tional interface card! This means it iseasy to switch system computers oreven to develop test methods orperform analyses in the office at yourconvenience. You always haveaccess to your test data.

Online Language SwappingNeedless to say, you can havetestXpert® II in your language ofchoice. testXpert® II speaks morethan one language – all you need todo is click the mouse in order tochange the language online. Regard-less of the language used for testing,a test report can be automaticallyprinted and e-mailed in a differentlanguage. Flexible testXpert® IIlanguage swapping offers internatio-nal teams language-neutral opera-tion of their testing machine andgreatly simplifies communication.

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Industry-oriented Terminologyand Data Export Capability

testXpert® II not only uses your lan-guage but it also adopts yourtechnical terminology. For example,symbols or variables that are specificto your industry (e.g. metals, plastics,rubber) are implemented throughoutthe software. This provides more re-levant, meaningful information foryour testing application. Today’squality assurance standards neces-sitate that the test results may beexported to a company’s centrallaboratory database. So we havecreated testXpert® II to commu-nicate reliably with your IT system byproviding flexible interfaces. All testresults can directly be processed,exported and archived. MS Officeintegration is achieved by means ofObject Linking Editing (OLE).

Strain Control

testXpert® II already incorporates thelatest ISO 6892-1 (2009) revision,which contains the first normativeinclusion of strain control in this inter-national standard. The test speedranges have narrow tolerances withthe aim of increasing reproducibilityin material property results, especiallyproof stress and yield point. This alsohas the effect of optimizing testtimes, which have a direct bearingon robotic testing systems with highspecimen throughput.

Select Test Standard

testXpert® II already contains thecorrect test program for everystandardized test. Simply select therequired test program – all para-meters are pre-configured inaccordance with standards and canalso be adapted as required. Fornon-standardized tests, testXpert® IIprovides arange of varied, powerfultesting programs, allowing the testsequence to be set up completelyas desired.

Testing

The individual data are displayed onthe monitor – online as part of thetest procedure, so you can followthe test procedure live. If desired youcan also incorporate an exactlysynchronized video recording.

The results are calculated during thetest so that the test procedure canbe process-controlled, e.g. by speedchange after determining the Young-modulus or the yield point. Only inthis manner can the test be per-formed quickly and in accordancewith the standard.

Fig. 1: Selection of pre-defined test results (tensile test)

Evaluation of Test Results

In testXpert® II you can create manydifferent screen layouts according toyour needs, for example with additio-nal graphs, various presentations ofthe testing curves, tables and additi-onal statistics. With one click youcan switch between the various lay-outs, thus changing the presentationof your test results

Validation of Testing Software

Reference data sets used for testingsoftware algorithms can be read intothe data import/export function. Ona European level, reference datasets of this type for tensile tests havebeen generated in a specified dataformat in the TENSTAND project andthe associated results have alsobeen internationally agreed.testXpert® II testing software andparameters for calculating resultscan be checked quickly and reliablyat any time using this data.

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r- and n-Value Determination

The r- and n-values are importantcharacteristics for the forming prop-erties of sheet metal. When sheetsare being rolled out these values areused to control the process andensure consistent sheet quality.Zwick testXpert® II supports r and n-value determination to ISO 10113and ISO 10275 in metal tensile testsand includes the revision of the twostandards concluded in 2007. Thesimultaneous use of axial andtransverse strain extensometers isessential for r-value determination(perpendicular anisotropy) on stan-dardized flat tensile specimens andsatisfies the conditions of thestandard. The n-value (hardeningexponent) is determined from thestress-strain curve. If all require-ments are fulfilled, these two resultscan be selected in the results menuand the standard-compliant resultswill appear in the display; they willalso be added to the results list forthe test report.

testXpert® II LIMS

Only testXpert® II offers this feature:an integrated Laboratory InformationManagement System (LIMS). Apowerful database is available toadminister your test results in orderto create and archive long-termstatistics and reports. All data ac-quired by testXpert® II are availableon any testing system in yourcompany.

Fig. 2: Long-term display of tensile strength over several days

Fig. 1: Display of determination of r- and n-values

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Fig 1: Load cell Xforce; design: multiple strain-gage

4.7 Load Cells

Load cells are available for accuratemeasurements from 0.02 N.Together with testControl digitalmeasurement electronics they offerthe following advantages:

• Measurement accuracy: Class 1(1 % of measured value) from 0.2to 100 % of nominal force andClass 0.5 (0.5 % of measuredvalue) from 1 to 100 % of nominalforce

• Insensitivity to parasitic influences(torque etc.)

• High flexural strength limit andtorsional strength limit againstbreak

• Zero point and characteristic valuetemperature compensation overthe entire measurement range

• Very high effective measured valueresolution and measurementfrequency in combination withtestControl

• General overload protectionthrough testXpert® II; mechanicalprotection also available for lowcapacity load cells

• Automatic identification andacquisition of all setting andcalibration parameters via thesensor connecting plug; load-cellchange does not require changingof set-up data or calibration

• Automatic zero point andsensitivity adjustment

• Load cells for testing in two testareas are available for capacitiesabove 10 kN (variant withmounting studs on both sides).

Configurations andRecommendations for Use

Depending on the testing situation,other aspects of load cells in additionto measuring accuracy are of impor-tance; when optional temperatureconditioning devices are in use (orduring use in factory shops with widetemperature gradients), zero point(TkO) and characteristic value (TkC)temperature compensation arerequired. With tensile or compressiontests, lateral forces and momentsoccur which must only have a slightinfluence on the measurement signalfrom the sensor. Zwick supplies twotypes of load cells to the following‘measurement principles’:

• Torsion ring load cell:The body of this rotationallysymmetrical load cell is a torsionring with ring-shaped strain-measuring spirals

Direction of tension

Direction of tension

• Design: multiple strain-gagebeamsMeasurement is performed bybeams in spoke formation.Characteristics:Insensitive to parasitic influencesand overloads.

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4.8 Specimen Grips

Specimen Grips for Tensile,Creep and Cyclic Tests

Metals testing is a large field. Itsmany applications are covered byZwick’s extensive range of specimengrips varying in design, test loadrange and testing temperature. Thespecific area of application ofspecimen grips depends on theiroperating principle and maximumpermitted test load; where tests areperformed in temperature or climaticchambers the temperature range inwhich the grips can be used is alsoan important consideration.

Load Transfer BetweenSpecimen and Specimen Grips

The operating principle defines thetype of load transfer between speci-men and specimen grips and mostgrips derive their names from this.With the majority of specimens, thetest load can only be transmittedindirectly, i.e. via friction. This meansthat the frictional force between theends of the specimen and the jawsof the specimen grips must alwaysbe greater than the test load. Theclamping forces necessary for this,which act perpendicularly to the testload, are generated externally (e.g.by pneumatic pressure) or derivedmechanically from the test load (self-clamping specimen grips). Jawbreaks in the clamping area, partic-ularly with specimens sensitive toclamping forces (wires and foil strips),are avoided by a reduction in thetest load before the clamping point.This is done through sling friction,achieved by leading the specimenends around curved friction surfaces(e.g. circle segments or rollers)before clamping them.

Gripping Force

Specimen grips with externallygenerated gripping force apply theset level of force throughout the test.With thick or soft specimens inparticular, however, specimen mate-rial can flow out of the clamping areaunder the effects of the test load(grip slippage) reducing the specimenthickness. With hydraulic and pneu-matic specimen grips the grippingforce nevertheless remains constant,as the pressure generator suppliesmore pressurized oil or compressedair. The gripping force of screw gripsdecreases to some extent, dependingon the stiffness and resilience of thegrips. Due to the high gripping forceof these specimen grips, specimenmaterial is forced out of the clampingarea when the grips are closed. Thespecimen is subjected to compres-sive loading and can be pre-damagedin this way. Similar behavior canalso occur with self-clamping speci-men grips, as the jaws move to-wards the center of the specimenon closing. This effect can be

avoided by appropriate control of thetesting machine drive on closing thegrips (zero force control). With self-clamping specimen grips the initiallylow gripping force increases in ac-cordance with the test load currentlyapplied and the operating principle.

Gripping Surface

Frictional force depends on both themagnitude of the gripping force andthe coefficients of friction of thecontact surfaces. For this reasoninterchangeable jaws or jaw insertswith various types of grippingsurfaces (differing shape, surfacestructure, material etc.) are providedfor many specimen grips.

Clamping Travel and OpeningWidth

Specimen grips with external grip-ping force generation have longclamping travel and thus also a largeopening width, leaving a larger freearea for convenient specimen in-sertion, even with thick specimens,and eliminating the need for ex-changeable jaws for different speci-men thicknesses.

Fig 1: Dependence of the clamping force onthe test load for different types of specimengrips

Clamping force

Tensile force

Hydr. and pneum. grips

Screw grips

Wedge-screw grips

Wedge grips

Pincer grips

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Overview of Specimen Grips

Selection criteria for specimen gripsCharacteristics/features

• Size (max. test load)Smallest version [kN] 10 0.02 0.02 2.5 0.02 0.5 0.5 25 10 0.5Largest version [kN] 2000 100 0.05 600 50 250 30 250 600 10

• Temperature rangeLower limit [°C] -70 -70 -15 -70 -70 -40 +20 -70 -70 -40Upper limit [°C] +250 +250 +80 +250 +250 +250 +1200 +250 +250 +250

Foils – ✓ – – ✓ ✓ – – – ✓

Sheets, thin sheets ✓ ✓ – ✓ ✓ ✓ – ✓ – ✓

Wires, fine wires ✓ ✓ ✓ ✓ ✓ ✓ – ✓ – –

Strips ✓ ✓ – ✓ ✓ ✓ – ✓ – –

Pipes ✓ ✓ – ✓ ✓ ✓ – ✓ – –

Dumbbells ✓ ✓ – ✓ ✓ ✓ ✓ ✓ ✓ –

Flat specimens ✓ ✓ – ✓ ✓ ✓ ✓ ✓ – ✓

Round specimens ✓ ✓ – ✓ ✓ ✓ ✓ ✓ ✓ –

Profiles ✓ – – – – – – – – –

Fig 1: Shoulder and threaded head grips Fig 3: Pneumatic grips Fig 5: Wedge-screw grips

Fig 2: Hydraulic grips Fig 4: Wedge grips Fig 6: High-temperature gripsS

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Spri

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Wedge g

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Hig

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gri

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Hyd

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Pneum

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Pin

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4.9 Extensometers

In most tensile tests the extensionagainst the test load has to bemeasured; in special cases thechange in width must also bemeasured. In flexure tests, themeasured quantity is the deflection.A variety of extensometer types arerequired to cope with differing speci-men shapes and dimensions, mate-rial properties (strength, rigidity,extensibility etc.) material character-istics to be determined, measuringaccuracies etc.

Requirements forExtensometers

The requirements for an extenso-meter are determined primarily bythe physical characteristics of thematerial to be tested. Other criticalfactors include the shape and di-mensions of the specimen togetherwith the relevant test standards andresults to be obtained.

Ambient conditions (temperature,light, vibration) and costs must alsobe taken into consideration, asshould the operating characteristicsof extensometers. Whatever theapplication, Zwick’s wide range ofextensometers has the right instru-ment for the job.

The following chart contains anoverview of the criteria affecting thechoice of extensometer.

Crosshead Travel Encoder

A digital crosshead travel encoder isstandard equipment on all ZwickStandard or Allround materials testingmachines. Its measuring signal isprimarily used to provide an actual

value for the drive system positionand speed control; however, it canalso be used for indirect extensionmeasurement .

Analogue Clip-onExtensometers(clip-on, manual)

The resolution of these extensome-ters, which can be attached man-ually or automatically (option) to thespecimen, is extremely high, buttheir test travel is relatively short.They are therefore predominantlyused for high precision determinationof tensile modulus (ISO 527-1) onrigid and reinforced plastics and todetermine Poisson’s Ratio (withsimultaneous measurement of ex-

Fig 1: Selection process of extensometers

Extensometer Portfolio

Measuring Priciple,Properties

Functionality(auto / manual)

Environmentalconditions

Purchase,Running Costs,

Ease of Use

Specific Test Application

Comparsion and selection processcriteria (“must have“ / “should have“)

Material(component)

Test Method,Standard

EnvironmentalInfluences

Budget

MaterialProperties

Specimen, TestSequence, Test Result

Temperature, Light,Noise

Purchasing,Running Costs

ExtenosmeterProperties

ExtensometersRequirements

tension and change in width). Fordetermination of Young’s modulusfrom a tensile test, measurement onboth sides with an extensometer isstrongly recommended.

Fig 2: Clip-on extensometer

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Fig 1: Digital Clip-on extensometer

Fig 3: Long stroke extensometer Fig 4: Optical extensometer

Digital Clip-on Extensometer(Clip-on, manual)

Unique to Zwick, these manuallyapplied extensometers feature highresolution and relatively long mea-surement travel, allowing them forexample to be used for precisedetermination of initial slope andproof stress to ISO 6892, EN 10002and ASTM E 8. Where specimenshave low extension, strains can bedetermined beyond proof stress, atmaximum stress and at break.

Biaxial Digital Clip-onExtensometer(clip-on, manual)

Manually applied axial/transversestrain extensometer with large mea-surement ranges and high resolutionfor r and n-value determination tostandard; fulfils the requirements ofClass 0.5 to EN ISO 9513.

Long-travel Extensometer

Used for measuring higher strains onthin, highly elastic wires. Drag forcesfor these applications are kept par-ticularly low, at less than or equal to0.2 N. The system has a high levelof insensitivity to specimens wrappingaround the sensor arms after break.

• High resolution and measurementaccuracy

• Low drag force• Robust construction

Optical Extensometer

Digital extensometer featuring non-contact measurement for tensiletests on wires and stranded wires;can also be used for applications intemperature chambers, in whichcase measurement takes place viaa heated window.

• No drag force• Reliable operation via signal

pattern recognition• Easy to handle

Fig 2: Biaxial digital Clip-on extensometer

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Fig 3: multiXtens

Fig 1: Macro extensometer

Fig 2: Transverse strain extensometer

Fig 4: optiXtens

Macro Extensometer

The Macro is the workhorse amongextensometers used in metals tes-ting. It is suitable for tensile, com-pression and flexure tests and alsofor cyclic tests on all metals. It isprimarily used on standard flat tensilespecimens, but also on thin stripsand foils from approx. 0.18 mm.

• Extremely robust construction• Measurement up to break, even

with heavy plate• Very high resolution and

measurement accuracy• Easily integrated into automated

systems

multiXtens

Fully automatic, multifunctional high-resolution digital extension measure-ment system for tensile, compres-sion, flexure and creep tests as wellas for cyclic tests on materials withlow to high extensions

Advantages:• Automatic gauge length setting• Automatic application and

detachment of sensor arms• Automatic centering between

specimen grips• Very low drag force• Deformation measurement until

specimen break without detachingsensor arms

• Crosshead contact protection• Exchangeable sensor arms for ten-

sile, compression and flexure tests• Automatic sensor recognition• Suitable for measurements in

temperature chambers• Upgradable for transverse strain

measurement

optiXtens

Fully automatic high-resolution,optical extensometer using the LaserSpeckle method. It is used for tensileand compression tests on materialswith low to high extensions, both atroom temperature and inconjunction with temperaturechambers.

Advantages:• Optical system not requiring

measurement marks• Easy to operate• No drag-force influence• Reliable, accurate deformation

measurement until specimenbreak

• Particularly suitable formeasurement in temperature andclimatic chambers

Transverse Strain Extensometer

For r-value determination the Macrocan be expanded with options fortransverse strain measurement. Theoptions contain 1, 2 or 4 measure-ment lines.

• Resolutions down to 0.01 µm.

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Fig 1: videoXtens

Fig 2: laserXtens

Extensometers: OverviewLong-stroke Optical Makro multiXtens optiXtens videoXtens1) laserXtens

extensometer

System digital digital digital digital2) laser- image laser-speckle evaluation speckle

Measuring range, mm 1000 – L0 1000 – L0 min. 75 700 – L0 500 – L0 50...200 40max. 160 700 – L0 (viewfield)

Resolution, µm 5 5 0.12...0.6 0.02...0.04 0.1 1 0.15Accuracy cl. 1 >_ 1mm cl. 1 >_ 3 mm class 0.5/14) class 0.5/14) class 0.5 class 1 class 1(ISO 9513) 1% or 1% or

0.01 mm3) 0.03 mm3)

Gauge lengths, mm 10...1000 10...900 10... >_ 5 >_ 10 >_ 5 1.5-220100/205/300

Drag force, N <_ 0.20 – <_ 0.050 <_ 0.015 – – –Autom. sensor arm ✓ – optional ✓ – – –Autom. L0 pre-set – ✓ ✓ optional ✓ ✓ ✓

1) Data for 25 mm lens, 2) Two measuring ranges, 3) Whichever value is greater, 4) Depending on feeler arm length

videoXtens

Non-contact, high-resolutionextensometer for tensile andcompression tests on all productforms of metals, especially onstandard specimens. Resolution andmeasurement range can be adaptedto current test conditions via easilychanged lenses. Simultaneoustransverse strain measurement ofthe specimen is optionally available.

Advantages:• Adaptable to various materials and

test conditions• Parallel measurement of

transverse strain (optional)• Reliable, accurate strain

measurement until specimenbreak

• Automatic gauge lengthrecognition

• Suitable for measurements intemperature chambers through aheated glass panel

laserXtens

laserXtens provides contact-freemeasuring of deformations on a widerange of materials, its measuringprinciple rendering gauge marksunnecessary. laserXtens is used fortensile and compression tests onmetals and components.

Advantages:• No specimen marking required• High resolution• Automatic gauge-length setting• Suitable for temperature chamber

testing• Parallel bi-axaial deformation

measurement• Optionally with transverse strain

measurement via integratedvideoXtens

• Suitable for testing smallspecimens at high resolution

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Application

During assembly of a materials tes-ting machine it is normal practice toincorporate the high-temperatureunit directly into the machine. Thistype of arrangement allows tensiletests to be carried out at both am-bient and raised temperatures.During testing at ambient tempera-ture, components such as thehigh-temperature furnace, high-temperature extensometer and pull-rod are simply swung out of the testarea. Using a centrally divided foldingfurnace allows the pull-rod in useto remain in the machine. After therod has cooled down it can be re-moved via a quick-change system.

4.10 High-TemperatureTesting Accessories

The high-temperature systemconsists of three main components:

• The swivel-mounted high-temperature furnace

• The high-temperatureextensometer, which can alsosimply be swiveled out of the testarea. It is moved up to thespecimen directly via a slit in thefurnace:

• The pull-rod, comprisingconnecting pieces for the quick-change system and the pull-roditself, via which the tensile load istransmitted into the furnace, andthe specimen grips at the end ofthe pull-rod.

In practice the most common speci-mens are threaded-end specimens,as described in DIN 50125 . Flatspecimens are produced from thinsheets and are held in positive-fittingflat-specimen grips. Standardizedspecimen grips in various materialsare available for these specimens inthe temperature range up to 1200 °C.Standardized units are also availablefor compression and flexure tests upto 1600 °C. The volumes present inthe furnace, the temperaturetolerances and hold-times specifiedin the standard; these plus heatingand cooling times mean that theduration of tests is more or less fixed- and decidedly time-consuming. Toshorten specimen throughput time,systems with several furnaces areavailable from the standard range.

Fig. 1: Materials testing machine with high-temperature furnace

Fig. 2: Quick-change system for high-temperature pull-rods

Fig. 3: Temperature controller

Fig. 4: Positive-fitting high-temperaturespecimen grips for flat specimens

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4.11 Creep Test

There is currently a great deal ofinterest in saving energy andreducing environmentally harmfulemissions. This is particularly thecase with turbine technology asused in power stations (e.g. gas andsteam turbine rotors) and aircraftturbine blades. One approach toincreasing efficiency is to raiseoperating pressure and temperature,for which the development of new,high-temperature-resistant materialsis vital. The creep test is one of themost important experiments fordescribing the high-temperaturebehavior of materials (standardized inothers ASTM E 139 and ISO 204and elsewhere), as proven materialproperties obtained over an ex-tended period are essential for thedesign and operation of high-temperature components. Creeptesting involves two different time-frames.

For short-term creep tests up to1000 h load-time, lead-screw-drivencreep testing machines are oftenused, in single or twin-screwdesigns. This type of drive allowsrelaxation tests (constant strain and

temperature) to be performed in ad-dition to creep tests. For long-termtests > 2500 h, dead weight machinesare often used – with load applica-tion usually by lever. It is essential forthe mechanical and thermal loadingof the specimen to be both constantand precise. Values determined areload time until break, creep strainlimits and high-temperature strain,e.g. creep strain. A comprehensiverange of solutions is available forstandard-compliant performance ofthese demanding tasks:

Mechanical Loading Unitcomprising load frame, drive andpull-rod:• Load frame with (one or two) lead-

screw drive(s) and precision guidefor precise, axial loading

• Load frame with lever loading andcalibrated dead weights

• Load frame with lever loading andload-cell-controlled drive

• Pull rod with optimum alignmentcharacteristics to ASTM E 1012

Electronics• High-resolution force and travel

measurement for optimum controlcharacteristics at very slow testspeeds.

High-temperature Unit• High-temperature furnace with six

thermal elements for optimumtemperature control

• Vertical furnace-positioning accor-ding to specimen strain

• Integrated universal self-optimizingHT controller guarantees obser-vance of strict limit values (e.g.ASTM E 139: +/- 2 K) for spatialand temporal specimen tempera-ture stability, with zero over-swing.Empirically determined set valuesfor each heat zone according tospecimen and furnace geometryare not necessary; all that is need-ed is to specify the temperatureset value in testXpert®

testXpert® II Testing Software• Freely selectable strain and force-

controlled load application• Creep and relaxation tests possible• Operator-friendly test performance

and results evaluation• Integrated temperature control of

HT controller• Optimized data acquisition and

security concept for creep tests

Fig. 1: Creep testing machine with two-lead-screw drive

Fig. 2: testXpert® II: specimen temperaturerising continuously to set values and active/automatic heat zone control

Fig. 3: Open furnace including thermalelements

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4.12 Robotic TestingSystems

Application

Robotic testing systems are used forefficient performance of large testseries on the same type of specimenand are available in the followingapplication-specific versions:

• roboTest A• roboTest C• roboTest F• roboTest L• roboTest R• roboTest P• roboTest I

Common Features

• Modular system allows flexiblecombination of individualcomponents

• Standardized control of robotictesting system via autoEdition2automation software with controlvia Profibus

• CE-compliant stand-alone system• Data exchange with any Zwick

materials testing machine via serialinterface

• Uses standard industrialcomputers.

Advantages for Users

• Minimal operator requirement (justload the specimen magazine!)

• High reproducibility of testconditions and test results

• Secure documentation andstatistical long-term monitoring

• Manually controlled tests alsopossible

• Modular system allows easyadaptation and expansion to meetspecific requirements.

Configurations and Operation

roboTest A‘roboTest A’ is attached to the loadframe and is designed for tensiletests on metals up to approx. 500 gweight per specimen. The magazinecan hold 20 specimens; all robotactuators are pneumaticallyoperated.

roboTest CThe ‘roboTest C’ testing system issuitable for tensile tests on dimen-sionally stable flat specimens weigh-ing 0.5 – 5 kg and can be attachedto 300 – 600 kN testing machines.The magazine usually containsaround 20 to 40 specimens, whichare held in portable carriers.

roboTest FThe ‘roboTest F’ robotic testingsystem is used for tensile tests(including non-rigid specimens). Itconsists of a movable base, with ho-rizontal upper and lower chainsforming an oval carousel equippedwith spring clamps or magnets forgripping specimens in a verticalalignment. Various grippingarrangements for differing specimenscan also be used in combination.Depending on the type of clampingand specimen, broken specimenscan be returned to the magazinearea.

Bild 2: roboTest LBild 1: roboTest F

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roboTest L‘roboTest L’ can be used for tensile,compression and flexure tests. Itconsists of a movable base pluselectronics units, a linear feed axis,pincer grips and optional movablemagazine table, the whole unit beingcontrolled by a programmable logiccontroller (PLC). Cross-section canbe measured automatically at up to3 places.

roboTest R‘roboTest R’ is used for tensile testsand comprises a 5 or 6-axisindustrial robot with a pneumaticgripper arm. The complete systemfeatures modular design, allowinghardness and roughness measuringequipment etc. to be integrated,together with a bar-code reader andcross-section measuring device.

roboTest PThe ‘roboTest P’ robotic testingsystem is used for tensile tests andfor hardness, roughness and layer-thickness measurements. Its largerdimensions and design allow severaltesting machines to be used in onesystem. The system consists of 3axes and a swiveling gripper unit andis controlled via a programmablelogic controller. A safety housing forthe whole system is required andcan be included in the quotation onrequest.

roboTest I‘roboTest I’ is used for impact testson Charpy specimens with a pendu-lum impact tester, at both plus andminus temperatures, to EN 10 045or ASTM E23. The specimen dimen-sions (length x width x thickness) areusually 55 x 10 x 5 - 10 mm and thestandard temperature range is from-180 to +300 °C. Specimen coolingis by means of nitrogen, whileheating is electric.

Data Processing Technology

Specimen data and test results fromall systems can be printed out andsaved or transferred via an interface,e.g. a local PC network, to a sub-ordinate computer system for reportgeneration and production moni-toring. Data transfer to MS Officeprograms, e.g. via ODBC, is alsopossible.

Fig. 1: roboTest R

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roboTest A C F I L P R• Specimen capacity 20 24/40 50...200 10/100 160 100...400 ca. 400

(typical)• Specimen characteristics

Round specimen ✓ ✓ ✓ – ✓ ✓ ✓

Flat specimen ✓ ✓ ✓ ✓ ✓ ✓ ✓

Non-dimensionallystable specimen – – ✓ – ✓ – –Max. weight 300 g 5 kg 500 g – 1 kg 10 kg 30 kg

• Specimen dimensions [mm]Shoulder/stripe width 6...25 max. 60 10...50 10 6...30 max. 50 max. 50Specimen thickness max. 20 max. 30 max. 5 5...10 max. 15 max. 60 max. 60(standard)Total length max. 300 max. 450 max. 350 55 max. 260 max. 500 max. 500

• OptionsThickness measurement manual manual manual – ✓ ✓ ✓

Specimen rest removal ✓ ✓ ✓ ✓ ✓ ✓ ✓

Barcode identification ✓ ✓ ✓ ✓ ✓ ✓ ✓

Roughness – – – – ✓ ✓ ✓

Hardness – – – – ✓ ✓ ✓

Cout thickness – – – – ✓ ✓ ✓

Automated hardness Test

ApplicationFor this test a hardness testinginstrument for Rockwell methodsHR15T, HR30T, HR45T, HRF, HRBand HRG is connected to a roboTestL, roboTest P or roboTest R robotictesting system.

Overview

Fig. 1: Automated hardness test with twohardness testers

Fig. 2: Automated tensile test with integrated hardness test

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Typical Round Specimens (Fig. 2, Specimen Type b)Standard Dimensions [mm]

d L0 D Lc LDIN EN 10002 (Anh. C) ≤4 100/200 L0 + 50DIN 50125, Form A 10 50 12 ≥60 ≥140

12 60 15 ≥72 ≥16016 80 20 ≥96 ≥205

ASTM E 8 12.5 50 608.75 35 45

JIS Z 2201 No 4 14 50 60

Typical Flat Specimens for Tensile TestStandard Dimensions [mm]

a b L0 B Lc L ΔbDIN EN 10002, Typ1 12.5 50 75 165 0.003DIN EN 10002, Typ 2 20 80 30 120 ≥250 0.052DIN 50114 ≤3 20 80 30 120 ≥250DIN 50125 3 8 30 12 38 ≥115

5 16 50 22 65 ≥1756 20 60 27 80 ≥2108 25 80 33 105 ≥260

JIS Z 2201 (13A) 20 80 30 120JIS Z 2201 (13B) 12.5 50 20 60JIS Z 2201/ 5) 25 50 30 60JIS Z 2201/1B) 25 200 30 220JIS Z 2201/1A) 40 200 220ASTM E 8 12.5 50 20 60 ≥200 0.05

40 200 50 225 ≥450 0.1

Specimen Blanking Machines for Cutting Forces from 500 to 1500 kNSeries RZ50 RZ65 RZ100 RZ150Structural shape C - frame O-frame O-frame O-frameCutting force [kN] 500 650 1000 1500Specimen throughput [1/min] 8 8 6 6Specimen thickness [mm] 0.2 - 6 0.2 - 6 0.2 - 6 0.2 - 8Max. powerconsumption [kVA] 4 4 8 8

4.13 Specimen Preparation

Specimen Blanking Machines

Blanking for economical productionof tensile specimens from sheetmetal. Work hardening by thecutting edge amounts to a maxi-mum of 10 % of specimen thicknessdue to the low cutting speed andthe shape of the blanking tool. Thesmall amount of stock – and with itthe work hardening – is removedusing the specimen grinder.

Zwick 7120 Specimen Grinder

Grinder for grinding specimen blanksto shape and size and removingwork-hardened areas. Height ofentire grinder unit (max. powerconsumption 0.75 kVA) is adjustable,enabling accurate grinding of parallelspecimen length.

Fig 1: Specimen blanking machineZwick RZ 150

Fig 2: Specimen types

Calculation of blanking forcewhen selecting specimenblanking machineBlanking force P in kN

If P ≥ 650 kN, then:

Ls = total cut length in mm σB = tensile strength in MPa α = specimen thickness in mm

Fig 3: Specimen grinder Zwick 7120

P = Ls x α x σB x 0,641000

P = Ls x α x σB x 0,81000

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5 Fatigue and ImpactTesting: Products andServices

Special Features

• Precisely aligned load framesfeaturing extremely high stiffness

• Hydrostatic bearings, making theactuators virtually frictionless - andalso wear-free

• LVDT extensometer with highresolution and linearity integratedcentrally in the actuator rod

Fig 1: Servo-hydraulic testing machineAmsler HC 25

Fig 3: Servo-hydraulic testing machineAmsler HA 100

Fig 2: Servo-hydraulic testing machineAmsler HB 250

• Precision strain-gauge load-cell formounting on actuator rod or fixingto crosshead as required

• Wide range of hydraulic powerpacks

• Comprehensive range of accesso-ries (specimen grips, extensometers,temperature chambers etc.)

5.1 Fatigue TestingMachines

Servo-hydraulic TestingMachines

Servo-hydraulic testing machines areuniversally applicable for materialsand component testing underpulsating or alternating load, withperiodic or random signals. Quasi-static and continuous loading arealso easily achieved.

Servo-hydraulic Testing Machines (STM) Standard versions1)

Model2) HC HB HA• Type/version table floor floor• Load frame nominal force [kN] 5 – 25 50 – 1000 50 - 500• Test stroke [mm] 100 100/250/400 100/250• Specimen length [mm] 100 – 700 100 – 1100 250 - 1500• Hydraulic power pack

* System pressure [bar] 210/280 210/280 210/280* Feed rate [l/min] 9 – 30 20 – 270 20 – 270

• Motor nominal power [kW] 5 – 20 11 – 160 11 – 160

1) Load frames available with higher rated actuators and different strokes on request2) Testing actuator mounted on upper crosshead of HC and HB frames, base-mounted on

HA frame

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Amsler HC-compact

The Amsler HC-compact servo-hydraulic testing machine consists ofa hydraulic power pack, test frameand test actuator and is suitable formaterials and component testingunder static and oscillating loads.

Advantages

• Space-saving design with inte-grated hydraulic power pack

• Whisper-quiet power pack allowinginstallation without additional noiseprotection measures in virtually anylaboratory

• Testing actuator mounted in topcrosshead permitting easy set-upfor flexure and component testing.

• T-slot platform hard-chromed fortests with corrosive media, e.g.saline solutions

• Seal-free testing actuator withhydrostatic bearings, guaranteeingsignificantly longer maintenance-free operation than with any otherdesign.

Amsler HCT and HBT Tensileand Compression/TorsionTesting Machines

The servo-hydraulic testingmachines in the Amsler HCT andHBT series are used to test thebehavior of materials andcomponents under combined tensileand compression/torsion loading.The tests can be performed withpulsating, cycling and static loading.

Features

Standard load frame from HC andHB range.• Tensile and compression/torsion

drive mounted in upper/fixedcrosshead and consisting of:- longitudinal actuator with hydro-

static bearings- length compensation- rotary actuator

• The length compensation allowsplay-free transmission of thetorque to the rod of the longitudinalactuator. The rotary activatorremains fixed and is not subject toaxial movement.

• Combined load cell/momentsensor

• Tests under discrete load can alsobe performed, e.g. axial load only.

Fig 1: Servo-hydraulic testing machineAmsler HC-compact

Fig 2: Tensiel, compression, torsion testingmachine Amsler HBT

SpecificationHC-compakt

• Test frame Fmax 25 kN• Testing Fmax 10 or 25 kN

actuator Stroke 100 or 250 mm• Hydraulic 9 l/min, 210 bar

power pack Noise level< 58 db(A)

SpecificationHCT 25/250 HBT 100/1

• Nominal force FN ±25 kN, stroke 100 mm FN ±100 kN, stroke 100 mm• Nominal moment MN ±250 Nm, MN ±1 kNm,

angle of rotation 280° angle of rotation 100°Additional figures on request

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Fig 1: HydroWin 96xx Controller

HydroWin 96xx

Outstanding features of the HydroWin96xx control and measurementelectronics include:

• 10 kHz closed-loop control anddata acquisition

• 19-bit A/D conversion with real-time linearization

• Real-time measurement channelsfor derived measurands also (e.g.totals or differences)

• 32-bit set-value generation for anyrequired functions up to 1kHz

• Adaptive control for non-linear testapplications (e.g. testing rubbercomponents or polymers)

• Multi-channel control(up to 9 control channels)

• Control of external units• Comprehensive basic and

application software.

Workshop 96 – Test Softwarefor HydroWin 96xx Controller

Workshop 96 is universal testingsoftware for fatigue and durabilitytests on materials and components,with a large number of applicationprograms for standard tests such asfracture toughness determination,low cycle fatigue, damper testingand so on. A valuable additionalfacility is upgrades for modernizingolder load frames from mostmanufacturers.

Function

The HydroWin 96xx digital controland data acquisition system plusWorkshop 96 software represent afully-integrated testing solution in auser-friendly Windows environment,providing test engineers with accessto all test-system control-options.

Fig 3: Workshop 96 screenshot

Fig 2: testXpert® screenshot of fatigue test on elastomer

Toolkit 96

Toolkit 96 supports Workshop 96and with the HydroWin 9600controller provides an integratedtesting environment with real-timegraphs, actual value displays(adjustable for running values), upperpeak, lower peak, peak to peak ormean values.

testXpert® Dynamic

Zwick also provides a range oftestXpert® software for specific test-ing applications, including low cyclefatigue, torsion testing, multi-stagecontinuous testing, and elastomer-metal component testing.Configuration 96

This software from the Workshop 96Framework enables the HydroWin96xx control and measurementelectronics to be configured to usemeasured-value transducers andchannels as required. Analog, digitaland mathematically-derived trans-ducers can be configured andassigned to channels. Connectionand disconnection of transducers isautomatically detected by theHydroWin 96xx controller and thesoftware.

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Vibrophore with Electro-Magnetic Resonance Drive

Zwick are suppliers of the world-famous Amsler HFP Vibrophore, thefirst version being introduced byAmsler in 1945. It is valued by testlaboratories in the automotive sectorfor its high-level performance andlow operating costs.

Special Features• Minimal energy consumption due

to resonance principle• No hydraulic power pack or other

installation outlay required• Maintenance-free operation• High testing frequencies, short test

times.

Applications• Dynamic tests to define the fatigue

strength of materials, e.g. fatiguetests in accordance with DIN 50100(S/N curve), in tensile, compres-sive, pulsating and alternating loadranges

• Fatigue strength and durability testson components such as springs,crankshafts, connecting rods,fasteners, steering knuckles etc.

Fig 2: Amsler HFP 250 VibrophoreFig 1: Testing of round specimen

• Fracture mechanics tests on CTor COD specimens

• Testing under various environ-mental conditions (temperature,aggressive media)

• Specimen pre-cracking for torsionand bending tests

• Production and quality control ofcomponents exposed to dynamicloading during their service life

Measurement and ControlElectronicsControl and monitoring of thesetesting machines is via VibroWincontrol and measurement elec-tronics, with test definition, displayand result evaluation by Zwick’sproven testXpert® software.

Fig 3: Testing of flat specimen

Vibrophore: SpecificationsModel, Amsler HFP 5,10 20,30 50,100,150,200,250 300,400,500,550• Load frame nominal force [kN] 5 – 10 ±20 to ±30 ±50 to ±250 ±300 to ±550• Max. force amplitude [kN] ±5 ±10 to ±15 ±25 to ±125 ±150 to ±225• Max. elastic specimen

deformation [mm] ±3 ±2 ±2 - ±3 ±2 - ±3• Frequency range [Hz] 35 - 300 35 - 300 35 - 300 35 - 300• Working area width [mm] 350 530 750 1000• Max. power consumption [kVA] 1 1 1 2.5

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5.2 Impact TestingMachines

Amsler HTM Servo-hydraulicHigh-speed Testing Machine

ApplicationServo-hydraulic high-speed testingmachines are predominantly used forhigh-speed penetration tests andhigh-speed tensile breaking tests.Speeds are easily selected over awide range from very slow to maxi-mum. Typical applications are aimedat material characteristics at highelongation rates, crash simulationsor better understanding of materialsin rapid forming processes. Theseinclude:• Tensile tests on flat and round

specimens• Tensile, peel and shear tests on

joining technologies

Control and MeasurementElectronicstestControl electronics plus testXpert®

software provide comprehensivetest-result evaluations, together withreport creation and data manage-ment.

Fig 2: High-speed testing machine Amsler HTM 5020Fig 1: testXpert® screenshot of a high-speedtest

Amsler HTM Servo-hydraulic High-speed Testing MachineSpecifications – standard versions*Model Amsler HTM

2512 5020 8020 16020• Hydraulic test load [kN] ± 25 ± 50 ± 80 ± 160• Max. speed [m/s] 12 20 20 20• Min. speed [mm/s] 1• End damping [mm] 50, both ends• Total stroke [mm] 350• Working stroke [mm] 250• System pressure [bar] 280• Actuator type Equal area actuator for tension/compression

with hydrostatic bearing mounting• Principle of load measurement piezo-electric• Principle of travel measurement incremental• Data acquisition 10 MHz, 12 bit,

4 channels (standard), 8 channels (option)* Additional figures on request

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Fig 3: Pendulum impact tester PSW 750Fig 2: Pendulum impact tester RKP 450

Pendulum Impact Testers

ApplicationPendulum impact testers are usedto determine impact energy, impactstrength and notched impactstrength of standardized metalspecimens and components. Thedesign and layout of our pendulumimpact testers conform to all rele-vant standards, allowing safe,reliable, Charpy and Izod testing,plus impact tensile tests to Brugger,in compliance with internationalapplication standards. Toaccommodate differing materials,specimen cross-sections and teststandards, pendulums with potentialenergy up to 750 joules, standard-compliant specimen supports andclamping fixtures are available; theseare easy to change, with no needfor time-consuming adjustment.

Features• Stiff, torsion-free frame with low-

friction pendulum mounting (theenergy goes into the specimen,not into the instrument base)

• CE-compliant safety devices pro-vide operator protection

• Good access to test area• Easy accessory exchange• Optional operator-friendly

testXpert® testing software.

AccessoriesPartly or fully automatic temperatureconditioning, feed and testing ofCharpy specimens at both positiveand negative temperatures toEN 10045 and ASTM E23. Speci-men cooling is by means of a two-stage cooling unit (cooling to max.-60 °C) or liquid nitrogen (cooling tomax. -180 °C), storage capacity upto 21 specimens. Heating takes

place electrically, while heat transferbetween specimens and the tem-perature conditioning unit is conduc-tive (solid body contact). A standard-compliant notch form is crucial forobtaining reliable results from theimpact test; Notch Vision providesswift, optical measurement of bothnotch and Charpy specimendimensions.

Pendulum Impact Tester Series RKP 450 PSW 750 PSW 750 (automatic)• Max. impact energy [J] 450, 300, 450 300, 450, 600, 750 300, 450, 600, 750• Angle of fall [degree] 150 161, 45 freely progammable• Impact velocity [m/s] 5.23 5.42 up to 5.42• Instrumentation optional optional optional

Fig 4: Pendulum impact tester PSW 750 withsemi-automatic specimen feeding andtempering

Fig 1: Notch Vision

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Drop Weight Testers

High-energy Drop WeightTesters for Testing PipelineSections

ApplicationThe American Petrol Institutionrequires pipes for use in pipelines tobe subjected to a drop-weight test.Standardized drop weight testersspecifically designed for this applica-tion can apply various impactenergies and speeds according torequirements. Zwick drop weighttesters can be used to test Batellespecimens to ASTM E 436-71T,API-RP 5 L 3 and EN 10274 ‘drop-weight tear test’.

Features• Modular system with six sizes and

two fall heights• Pneumatic specimen feed plus tool

fitting outside test area• Pneumatic specimen gripping, no

mechanical thickness adjustmentrequired

• Test area is mechanically andelectrically protected via a safetycircuit – test cannot begin until allsafety contacts have beenmonitored; additional independentpneumatically operated safetylocking bar prevents test areaaccidents

• Touch-screen operation withelectronic display of fall height,impact energy, drop weight andimpact velocity

• Infinitely adjustable fall heightposition is automaticallyimplemented after input of dropweight and impact energy

• Drop weight is divided into individu-al weights for adjusting impactenergy

Fig 1: High-energy drop weight tester DWT 40 (max drop height 5 m)

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Series DWT20-2.5 DWT20-5 DWT30-2.5 DWT30-5 DWT40-2.5 DWT40-5 DWT60-5 DWT80-5 DWT100-5

20,000 J 20,000 J 30,000 J 30,000 J 40,000 J 40,000 J 60,000 J 80,000 J 100,000 J

• Max. drop height [m] 2.5 5 2.5 5 2.5 5 5 5 5

• Drop weight approx. [kg] 820 410 1225 613 1632 816 1225 1630 2040

• Weight [kg] 6100 6350 6700 7050 7150 7450 9300 9800 11,800

• Speed of drop [m/s] 7 9.9 7 9.9 7 9.9 9.9 9.9 9.9

• Speed of weight lift

fast [m/min] 18 18 18 18 18 18 18 18 18

slow [m/min] 3 3 3 3 3 3 3 3 3

• Max. height approx. [mm] 5900 8000 5900 8000 5900 8000 8300 8300 8300

• Power supply [kW] 11 7 11 7 11 7 11 11 11

• Air pressure [bar] 8 8 8 8 8 8 8 8 8

• Air consumption [l/min] 600 600 600 600 600 600 1000 1000 1000

• Air consumption

Temperature [°C] -80 -80 -80 -80 -80 -80 -80 -80 -80

Max. deviation of temperature ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1

• Number of specimens 3 3 3 3 3 3 3 3 3

• Dimensions of specimens [mm] 50 x 77 x 305 50 x 77 x 305 50 x 77 x 305 50 x 77 x 305 50 x 77 x 305 50 x 77 x 305 50 x 77 x 305 50 x 77 x 305 50 x 77 x 305

Fig 1: Pellini drop weight tester P550

Pellini Drop Weight Testers

ApplicationDrop weight test for investigation ofbrittle fracture tendency of steels toSEP 1325 and ASTM E208 toW.S.Pellini.

Energy RequiredMax. 550 - 1630 J, drop weight22.5 - 136 kg

Zwick P550 Pellini drop weight tester• Testing P2, P3 and P4 specimens• Max. fall height: 1000 mm, infinitely

adjustable• Total height: approx. 2650 mm

• Drop weight: 34 - 56 kg• Impact energy: 340 - 550 J• Impact velocity: max. 4.4 m/s• Power consumption: 2 kW• Air pressure: 8 bar• Total weight: 1000 kg• Manual specimen feed• Drop weight divided into individual

flat weights• Drop weight measurement via

load cell• Automatic calculation of impact

energy• Automatic pick-up and raising of

fall weight via cable winch• Safety door with safety locking-bar• Touch operating panel.

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6 Modernization Packagesfor all Makes of MaterialsTesting Machines

Zwick ZMART.PROModernization and RetrofitTechnology

Modernizing a testing system can bean economical alternative to buyinga new one, especially with testingmachines with high nominal force,special load frames or complex pe-ripherals. Many of the existing com-ponents such as extensometers orspecimen grips can be adapted tothe new technology and continue inuse.

Whoever built it – Zwick has theright solution for every make

Zwick provides modular moderniza-tion kits which can be adaptedindividually to suit a wide range ofrequirements.

Modernization Packages forMaterials Testing Machineswith Electro-Mechanical andHydraulic Drives

Quasi-static materials testing ma-chines (with electro-mechanical orhydraulic drive) can be re-equippedto state-of-the-art level using thetestControl modernization package.

Modernization involves the followingbasic elements:• testControl digital control and

measurement technology• testXpert® testing software• Maintenance-free, precision-

controlled AC drive• Adaptation of existing sensors.

Additional elements for hydraulicmaterials testing machines:• Proportional or servo valves• New hydraulic power pack or

adaptation of existing hydrauliccomponents.

Modernization Packages forServo-Hydraulic Testing Systems

Zwick’s HydroWin 96 and ControlCube modernization packages providea wide range of options for moderniz-ing servo-hydraulic testing systems ofmany different makes.

The conversion kits comprise thefollowing components:• HydroWin 96 and Control Cube

digital measurement and controlelectronics

• testXpert®/ Workshop 96 testingsoftware

• New hydraulic power pack oradaptation of existing components.

Zwick also provides special moderni-zation options for vibrophores, high-speed test rigs, creep test machinesand pendulum impact testers.

New from Old

We only use components from thecurrent production ranges, providingyour newly modernized machinewith the same level of technology asa comparable new machine.

testXpert® is standard software, soboth new and modernized machinesare equipped with the same operat-ing platform.Following modernization, users enjoyrenewed long-term reliability,guaranteed spare-part supply andaccess to the whole Zwick acces-sory program.

Detailed information regarding con-trol and measurement electronicsused can be found on pages 38 and57.

Fig 1: Servo-hydraulic testing machineZwick REL2041 after the modernizationwith HydroWin 96XX

Fig 2: Materials testing machine Zwick 1455after the modernization with testControl

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7 Zwick Services

Applications Laboratory andContract Testing

In the last few years Zwick's appli-cations laboratory has become to acompetence-center of materalstesting with active scientificexchange.

Functions:• Demonstrations and pre-testing• Performing and evaluating tests on

customers’ behalf

Services:• Use of full Zwick portfolio• Design and adaptation of specific

testing devices• Documentation and interpretation

of component failure• Access to expert knowledge of

highly experienced staff• Evaluation and documentation of

tests• Fast testing service to international

standards, works standards andspecial regulations

• Advice on products, testingmethods and test performance

Laboratory for Fatigue andImpact Testing

• Determining S-N curves for fatiguestrength measurement of bonds,structures, and weld seams

• Fatigue test investigations undermulti-axial load

• Fatigue strength investigationsunder in-service loadings- single and multi-stage testing- testing under temperature

(60 °C to +1200 °C)- connecting rod testing under

simulated engine conditions- corrosive media on request

• Determining cyclic materialbehavior (LCF)

• Determining fracture mechanicalcharacteristic values

• Performing tests under impacttest force

• Application of measuring methodsto obtain the relevant mechanicalvalues (crack propagation, crackdetection, local strains, tempera-ture sequence etc.) for specimensand components

Laboratory for Quasi-StaticApplications

• Tensile, compression, flexure andtorsion testing

• Testing under temperature (-40 °C to +200 °C)

• Testing in high temperature range(+200 °C to +900 °C)

• Determining impact strength• Hardness testing• Melt index testing• Component testing• Viscosity testing• Fracture mechanics testing

Fig 1: Zwick fatigue and impact testing laboratory Fig 2: Zwick laboratory for quasi-staticapplications

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Further Services

Worldwide Service

Customer satisfaction is our firstpriority at Zwick Roell AG. Localservice organizations in over 50countries work to ensure optimumutilization and maximum availability ofyour testing system.

Engineer Consultation Service

New testing assignments with chan-ging requirements, building orupgrading a testing laboratory - onlywith the aid of specialists can you besure of getting what you want.Experienced Zwick engineers adviseat the planning stage of complexprojects and then help you achievethe reality.

Demonstration

There are many factors to considerbefore deciding to acquire amaterials testing system andaccessories. To make that decisioneasier, the application technologylaboratory at Zwick's headquartersoffers you the opportunity toexperience various solutions to awide range of testing situations.

Test drive

For new, altered or highly complexapplications, Zwick offers you the op-portunity to carry out a practical test.The application technology laboratory'sexperts and comprehensive range ofequipment are at your disposal.

Application Technology Seminars

Active co-operation with associatesin research and technology enablesthe Zwick Academy to organizeseminars on the basic principles ofmaterials testing, its applications andthe current level of knowledge.

Pre-Delivery Inspection

Before final delivery of a machine,customers have the opportunity tocarry out a pre- delivery inspectionat our premises, where they cansatisfy themselves regarding scopeof delivery and try out the functionsstipulated in the order. We alsoprovide an introduction to operatingthe system.

Transport

If required, Zwick Service will, aspart of the commissioning process,provide full transport supervision. Wecan also provide business-to-business transport and deliver themachine to the desired location atyour premises.

Installation

With several thousand successfulcommissionings under our belt, youcan rely on Zwick Service to providethe best possible installation servicefor machine and/or accessories.Pre-handover function tests in thecustomer's presence help makeinstallation trouble-free.

Hardware Familiarization

Nothing is left to chance at ZwickService when a new system iscommissioned. Professional, system-atically constructed checklists helpyou get the most out of our products.

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Software Familiarization

Specially produced checklists usingconcrete examples from everydaypractice help you become familiarwith our software, with results beingsaved for later use. Alternatively, weoffer a 2-stage induction course,consisting of a basic introduction aspart of the commissioning process,followed by an expanded inductionat a later point in time.

Machine Relocation

Zwick Service will organize the relo-cation of your testing machine fromstart to finish. Our experiencedproject management team will takecare of the detailed planning ofdisassembly, transport and recom-missioning. Zwick will see to it thatyour testing machine is ready andwaiting at your new premises.

Software Adaptation

With our software engineers' depthof expert knowledge and manyyears of experience, you can rely onZwick to deliver programming per-fectly adapted to your individualrequirements. Working closely withour customers, we identify theirtesting requirements and – still inclose collaboration – deliver the rightpackage for the job.

Product Training

Qualified trainers with industry ex-perience provide product training.We also offer individual trainingtailored to customers' requirements.This is available in-house or at ourpremises.

Hotline

First priority is for your testing ma-chine to be in perfect working order.Should faults develop in your machineor software, in spite of their highquality, our expert staff are ready tohelp you via the Zwick Hotline. Yourcall will be returned in the shortestpossible time.

SupportDesk

For further advice or assistance,such as technical or software sup-port, the Zwick SupportDesk is inmany cases a better option than anon-the-spot visit. Our experiencedstaff will use their wide-rangingtechnical knowledge to provide youwith an answer speedily andeffectively.

Rental

Whether for short-term testingrequirements or just to try them out,Zwick Service has the specimengrips you need.

Maintenance

Zwick Service can perform thenecessary scheduled maintenanceof machines and accessories asdetailed in the operating manual andwill also ensure that service intervalsare maintained.

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Servicing

Zwick Service helps you reducedowntime significantly through regu-lar servicing of your testingmachines.

The condition of the machine is re-corded at the service and necessaryrepairs are carried out and wearparts replaced immediately, wherepossible. The service engineer willalso advise on preventive and/or pre-cautionary measures.

Repairs

If, in spite of careful servicing andmaintenance, a fault develops in amachine, one of our many serviceengineers will be with you in theshortest possible time, while spareparts can be delivered within 24hours.

Calibration

Zwick's calibration service isaccredited by DKD1), UKAS2),COFRAC3) and A2LA4) to DIN ENISO/IEC 17025 for on-site calibrationof materials testing machines.

The reference measuring equipmentused is regularly recalibrated. De-pending on the customer's require-ments, either a works calibration(Zwick calibration certificate), ISOcalibration (Zwick certificate withdocumentation showing measuringequipment supervision to ISO9001)or DKD calibration (DKD certificate) isperformed.

If necessary, the testing machinesand associated sensors will beadjusted during calibration.

1) DKD: Deutscher Kalibrier-Dienst2) UKAS: United Kingdom Accreditation

Service3) COFRAC: Comité Français d´Accréditation4) A2LA: American Association for

Laboratory Accredition

Software Upgrade/Update

An update gives you access to theongoing development of testXpert®

software and opens the door to anexpanded range of functions.Changes to testing standards arealso incorporated into the latestversions.

Upgrading from an old DOS operat-ing system to the latest Windowsequivalent provides a secure, reliableroute to the new technology. Up-grade from testXpert® to testXpert® IIand enjoy access to all the latesttestXpert® developments, with theirmany benefits for everyday use.

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8 Standards and Testing Devises

No. Test Standard Type of test Type Test device Page

4 ASTM E Calibration of load measuring systems Testing equipment Load cells -

8 ASTM E Preparation of tensile samples Sample preparation Machines for sample preparation 54

8 ASTM E Tensile test at ambient temperature Tensile, compression, and bending tests Materials testing machines 28

8 ASTM E High temperature tests Creep and endurance tests Materials testing machines 28

9 ASTM E Compression test Tensile, compression, and bending tests Materials testing machines 28

10 ASTM E Hardness acc. to Brinell Hardness tests Hardness testing machines 34

18 BS Tensile test at ambient temperature Tensile, compression, and bending tests Materials testing machines 28

18 ASTM E Hardness acc. to Rockwell Hardness tests Hardness testing machines 34

21 ASTM E Tensile test at elevated temperatures Tensile, compression, and bending tests Materials testing machines 28

23 ASTM E Standard test methods notched bar impact testing Testing equipment Pendulum impact testers 60

23 ASTM E Notched bar impact test Dynamic impact tests Pendulum impact testers 60

92 ASTM E Hardness acc. to Vickers Hardness tests Hardness testing machines 34

148 -1 ISO Notched bar impact test Dynamic impact tests Pendulum impact testers 60

148 -2 ISO Testing and Calibration of

pendulum impact tester Charpy Dynamic impact tests Pendulum impact testers 60

190 ASTM E Flexure test on welded seams Tensile, compression, and bending tests Materials testing machines 28

208 ASTM Drop Weight Tests NIL-Duct. trans. temp. Dynamic impact tests Drop Weight Testers 61

230 / 201 VDA Draw-bead test Other tests Draw bead accessories 15

290 ASTM E Flexure test on welded seams Tensile, compression, and bending tests Materials testing machines 28

345 ASTM E Tensile test on metal foils Tensile, compression, and bending tests Materials testing machines 28

370 ASTM A Tensile test at ambient temperature Tensile, compression, and bending tests Materials testing machines 28

376 DIN EN ISO Calibration of load measuring systems Testing equipment Load cells 42

384 ASTM Hardness acc. to Knoop Hardness tests Hardness testing machines 34

399 ASTM E Fracture mechanics tests Creep and endurance tests Materials testing machines 28

416 ASTM A Tensile test on prestressing steels Tensile, compression, and bending tests Materials testing machines 28

436 ASTM Drop Weight Tear Tests of ferritic steels Dynamic impact tests Drop Weight Testers 61

488 DIN Tensile test on reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

606 ASTM E Practice Strain Controlled Fatique Testing Creep and endurance tests Vibrophores 58

643 ASTM E Ducility test acc. to Olsen Other tests Sheet metal testing machines 33

696 DIN Testing of steel wires for reinforcement of concrete Creep and endurance tests Vibrophores 58

739 SI Testing reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

783 ISO High temperature tests Creep and endurance tests Materials testing machines 28

895 DIN EN Tensile test of welds Tensile, compression, and bending tests Materials testing machines 28

898 ISO Tensile test of screws Tensile, compression, and bending tests Materials testing machines 28

910 DIN EN Flexure test on welded seams Tensile, compression, and bending tests Materials testing machines 28

1023 DIN EN Flexure test on pipes and pipe segments Tensile, compression, and bending tests Materials testing machines 28

1043 DIN EN Hardness at welded joints Hardness tests Hardness testing machines 34

1143 ISO Rotating bar bending fatigue tests Creep and endurance tests Rotating Bend Fatigue Test Systems 22

1455 DIN EN ISO Instrumented Charpy impact test Dynamic impact tests Pendulum impact testers 60

1669 DIN EN Earing test for sheets and strips Other tests Sheet metal testing machines 33

2002 -7 DIN EN Hardness testing for aerospace Hardness tests Hardness testing machines 34

2201 JIS Z Preparation of tensile samples Sample preparation Machines for sample preparation 54

2204 JIS Z Flexure test Tensile, compression, and bending tests Materials testing machines 28

2241 JIS Z Tensile test at ambient temperature Tensile, compression, and bending tests Materials testing machines 28

2248 JIS Z Flexure test Tensile, compression, and bending tests Materials testing machines 28

2248 JIS Z Method of bond test Tensile, compression, and bending tests Materials testing machines 28

3112 JIS Tensile test on reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

4449 BS Tensile test on reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

4449 BS Method of bond test Tensile, compression, and bending tests Materials testing machines 28

4482 BS Tensile test on reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

Standard

69

4483 BS Tensile test on reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

4506 DIN ISO Compression test on hard metals Tensile, compression, and bending tests Materials testing machines 28

4545 ISO Hardness acc. to Knoop Hardness tests Hardness testing machines 34

5896 BS Tensile test on prestressing steels Tensile, compression, and bending tests Materials testing machines 28

6506 DIN EN ISO Hardness acc. to Brinell Hardness tests Hardness testing machines 34

6507 DIN EN ISO Hardness acc. to Vickers Hardness tests Hardness testing machines 34

6508 DIN EN ISO Hardness acc. to Rockwell Hardness tests Hardness testing machines 34

6603 -2 DIN EN ISO High-speed tensile test and impact penetration test Dynamic impact tests High-speed testing machines 59

6892 ISO Tensile test at ambient temperature Tensile, compression, and bending tests Materials testing machines 34

7438 ISO Flexure test Tensile, compression, and bending tests Materials testing machines 28

7500 -1 DIN EN ISO Calibration of load measuring systems Testing equipment Load cells 42

8491 ISO Testing of pipes Tensile, compression, and bending tests Materials testing machines 28

9283 DIN EN ISO Industrial robot testing methods Testing equipment Tensile, compression, and

bending testing machines 28

9513 DIN EN ISO Calibration of extensometers Testing equipment Extensometers -

10002 -1 DIN EN Preparation of tensile samples Sample preparation Machines for sample preparation 54

10002 -1 DIN EN Tensile test at ambient temperature Tensile, compression, and bending tests Materials testing machines 28

10002 -5 DIN EN Tensile test at elevated temperatures Tensile, compression, and bending tests Materials testing machines 28

10045 -1 DIN EN Charpy impact test Dynamic impact tests Pendulum impact testers 60

10045 -2 DIN EN Testing and Calibration of

pendulum impact tester Charpy Testing equipment Pendulum impact testers 60

10080 DIN EN Tensile test on reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

10113 ISO Determination of r-value Tensile, compression, and bending tests Materials testing machines 28

10138 DIN EN Tensile test on prestressing steels Tensile, compression, and bending tests Materials testing machines 28

10232 DIN EN Testing of pipes Tensile, compression, and bending tests Materials testing machines 28

10237 DIN EN Testing of pipes Tensile, compression, and bending tests Materials testing machines 28

10274 DIN EN Drop weight test Dynamic impact tests Drop Weight Testers 61

10275 ISO Determination of n-value Tensile, compression, and bending tests Materials testing machines 28

10606 ISO Tensile test on reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

12135 ISO Fracture mechanics tests Creep and endurance tests Materials testing machines 28

14577 DIN EN ISO Hardness acc. to Martens Hardness tests Hardness testing machines 34

15579 ISO Tensile test at low temperatures Tensile, compression, and bending tests Materials testing machines 28

20482 DIN EN ISO Ducility test acc. to Erichsen Other tests Sheet metal testing machines 33

22252 DIN Tensile test of chains Tensile, compression, and bending tests Materials testing machines 28

24506 DIN EN Compression test on hard metals Tensile, compression, and bending tests Materials testing machines 28

36065 UNE Testing reinforcing steel Tensile, compression, and bending tests Materials testing machines 28

50100 DIN Fatigue tests (Wöhler tests) Creep and endurance tests Servo-hydraulic testing machines 55

50106 DIN Compression test Tensile, compression, and bending tests Materials testing machines 28

50111 DIN Flexure test (folding test) Tensile, compression, and bending tests Materials testing machines 28

50113 DIN Rotating bar bending fatigue tests Creep and endurance tests Rotating Bend Fatigue Test Systems 22

50118 DIN Creep tests with tensile stress Creep and endurance tests Creep testing machines 50

50125 DIN Preparation of tensile samples Sample preparation Machines for sample preparation 54

50141 DIN Shear test Tensile, compression, and bending tests Materials testing machines 28

50151 DIN Flexure test on sheet metal (0.05...1 mm thick) Tensile, compression, and bending tests Materials testing machines 28

50154 DIN Tensile test on metal foils Tensile, compression, and bending tests Materials testing machines 28

50155 DIN Earing test for sheets and strips Other tests Sheet metal testing machines 33

51222 DIN Requirements to pendulum impact tester <_ 50 J Testing equipment Pendulum impact testers 60

65150 LN Shear test Tensile, compression, and bending tests Materials testing machines 28

84912 ISO Flexure test on pipes and pipe segments Tensile, compression, and bending tests Materials testing machines 28

5L API Tensile test at ambient temperature Tensile, compression, and bending tests Materials testing machines 28

5L3 API-RP Drop Weight Tear Tests on pipe line Dynamic impact tests Drop Weight Testers 61

No. Test Standard Type of test Type Test device PageStandard

70

1. Testing equipment Calibration of load measuring systems ASTM E 4 Load cells -

Calibration of extensometers DIN EN ISO 9513 Extensometers -

Standard test methods notched bar impact testing ASTM E 23 Pendulum impact testers 60

Calibration of load measuring systems DIN EN ISO 376 Load cells -

Industrial robot testing methods DIN EN ISO 9283 Tensile, compression, and

bending testing machines 51

Requirements to pendulum impact tester <_ 50 J DIN 51222 Pendulum impact testers 60

Testing and Calibration of pendulum impact tester Charpy DIN EN 10045-2 Pendulum impact testers 60

Calibration of load measuring systems DIN EN ISO 7500-1 Load cells -

2. Sample preparation Preparation of tensile samples DIN EN 10002-1 Machines for sample preparation 54

Preparation of tensile samples DIN 50125 Machines for sample preparation 54

Preparation of tensile samples JIS Z 2201 Machines for sample preparation 54

Preparation of tensile samples ASTM E 8 Machines for sample preparation 54

3. Tensile, compression, Tensile test at ambient temperature DIN EN 10002-1 Materials testing machines 28

and bending tests Tensile test at ambient temperature ISO 6892 Materials testing machines 28

Tensile test at ambient temperature API 5L Materials testing machines 28

Tensile test at ambient temperature JIS Z 2241 Materials testing machines 28

Tensile test at ambient temperature BS 18 Materials testing machines 28

Tensile test at ambient temperature ASTM A 370 Materials testing machines 28

Tensile test at ambient temperature ASTM E 8 Materials testing machines 28

Tensile test at elevated temperatures DIN EN 10002-5 Materials testing machines 28

Tensile test at elevated temperatures ASTM E 21 Materials testing machines 28

Tensile test at low temperatures ISO 15579 Materials testing machines 28

Tensile test on reinforcing steel DIN 488 Materials testing machines 28

Tensile test on reinforcing steel BS 4449 Materials testing machines 28

Tensile test on reinforcing steel BS 4482 Materials testing machines 28

Tensile test on reinforcing steel BS 4483 Materials testing machines 28

Tensile test on reinforcing steel JIS 3112 Materials testing machines 28

Tensile test on reinforcing steel ISO 10606 Materials testing machines 28

Tensile test on reinforcing steel DIN EN 10080 Materials testing machines 28

Testing reinforcing steel SI 739 Materials testing machines 28

Testing reinforcing steel UNE 36065 Materials testing machines 28

Tensile test on prestressing steels DIN EN 10138 Materials testing machines 28

Tensile test on prestressing steels BS 5896 Materials testing machines 28

Tensile test on prestressing steels ASTM A 416 Materials testing machines 28

Tensile test on metal foils ASTM E 345 Materials testing machines 28

Tensile test on metal foils DIN 50154 Materials testing machines 28

Determination of n-value ISO 10275 Materials testing machines 28

Determination of r-value ISO 10113 Materials testing machines 28

Tensile test of welds DIN EN 895 Materials testing machines 28

Tensile test of chains DIN 22252 Materials testing machines 28

Tensile test of screws ISO 898 Materials testing machines 28

Shear test DIN 50141 Materials testing machines 28

Shear test LN 65150 Materials testing machines 28

Testing of pipes DIN EN 10232 Materials testing machines 28

Testing of pipes DIN EN 10237 Materials testing machines 28

Testing of pipes ISO 8491 Materials testing machines 28

Compression test DIN 50106 Materials testing machines 28

Compression test ASTM E 9 Materials testing machines 28

Compression test on hard metals DIN ISO 4506 Materials testing machines 28

Compression test on hard metals DIN EN 24506 Materials testing machines 28

Type Type of test Test Standard No. Test device Page

71

3. Tensile, compression, Flexure test ISO 7438 Materials testing machines 28

and bending tests Flexure test JIS Z 2248 Materials testing machines 28

Flexure test JIS Z 2204 Materials testing machines 28

Flexure test (folding test) DIN 50111 Materials testing machines 28

Flexure test on welded seams DIN EN 910 Materials testing machines 28

Flexure test on welded seams ASTM E 190 Materials testing machines 28

Flexure test on welded seams ASTM E 290 Materials testing machines 28

Flexure test on sheet metal (0.05 … 1 mm thick) DIN 50151 Materials testing machines 28

Flexure test on pipes and pipe segments DIN EN 1023 Materials testing machines 28

Flexure test on pipes and pipe segments ISO 84912 Materials testing machines 28

Method of bond test JIS Z 2248 Materials testing machines 28

Method of bond test BS 4449 Materials testing machines 28

4. Hardness tests Hardness acc. to Vickers DIN EN ISO 6507 Hardness testing machines 34

Hardness acc. to Vickers ASTM E 92 Hardness testing machines 34

Hardness acc. to Brinell DIN EN ISO 6506 Hardness testing machines 34

Hardness acc. to Brinell ASTM E 10 Hardness testing machines 34

Hardness acc. to Rockwell DIN EN ISO 6508 Hardness testing machines 34

Hardness acc. to Rockwell ASTM E 18 Hardness testing machines 34

Hardness acc. to Knoop ISO 4545 Hardness testing machines 34

Hardness acc. to Knoop ASTM 384 Hardness testing machines 34

Hardness acc. to Martens DIN EN ISO 14577 Hardness testing machines 34

Hardness at welded joints DIN EN 1043 Hardness testing machines 34

Hardness testing for aerospace DIN EN 2002-7 Hardness testing machines 34

5. Creep and endurance tests High temperature tests ISO 783 Materials testing machines 28

High temperature tests ASTM E 8 Materials testing machines 28

Fracture mechanics tests ISO 12135 Materials testing machines 28

Fracture mechanics tests ASTM E 399 Materials testing machines 28

Rotating bar bending fatigue tests DIN 50113 Rotating Bend Fatigue Test Systems 22

Rotating bar bending fatigue tests ISO 1143 Rotating Bend Fatigue Test Systems 22

Fatigue tests (Wöhler tests) DIN 50100 Servo-hydraulic testing machines 56

Creep tests with tensile stress DIN 50118 Creep testing machines 50

Practice Strain Controlled Fatique Testing ASTM E 606 Vibrophores 58

Testing of steel wires for reinforcement of concrete DIN 696 Vibrophores 58

6. Dynamic impact tests Charpy impact test DIN EN 10045-1 Pendulum impact testers 60

Instrumented Charpy impact test DIN EN ISO 1455 Pendulum impact testers 60

Notched bar impact test ASTM E 23 Pendulum impact testers 60

Notched bar impact test ISO 148-1 Pendulum impact testers 60

High-speed tensile test and impact penetration test DIN EN ISO 6603-2 High-speed testing machines 59

Drop weight test DIN EN 10274 Drop Weight Testers 61

Drop Weight Tear Tests on pipe line API-RP 5L3 Drop Weight Testers 61

Drop Weight Tear Tests of ferritic steels ASTM 436 Drop Weight Testers 61

Drop Weight Tests NIL-Duct. trans. temp. ASTM 208 Drop Weight Testers 61

7. Other tests Ducility test acc. to Erichsen DIN EN ISO 20482 Sheet metal testing machines 33

Ducility test acc. to Olsen ASTM E 643 Sheet metal testing machines 33

Earing test for sheets and strips DIN 50155 Sheet metal testing machines 33

Draw bead test VDA 230/201 Draw bead accessories 15

Earing test for sheets and strips DIN EN 1669 Sheet metal testing machines 33

Type Type of test Test Standard No. Test device Page

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