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Intelligent testing
Creep Testing
with Messphysik
Peter Ruchti
Hereford, September 2012
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Agenda
Creep testing with Messphysik
Actual potential
Furnace and tem erature controller
Working principles metals
Working principles plastics / composites
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
2
Customer projects on other materials
Customer projects on metals
Customer projects on plastics
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Actual potential
Today there is a high need of energy saving and reduction of emissions.With higher temperature (T) and pressure (p) the efficiency of HT-systems will be
better and therefore energy and emissions can be saved or reduced.
HT-Power plant Aerospace Petrochemical Industry
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
3
960 …. 1200 °C > 1200°C
50 bar …. > 110 bar
500 …. 650 °C > 700°C
170 bar …. > 350 bar
Steam turbine Gas turbine
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Actual potential
Plastic used as a basic material in several industries combines some importantadvantages: constant quality, reliability and in distinctive energy efficiency.
Engineering plastics and fiber-reinforced plastics enable new developments in:
Automotive Aerospace Wind energy
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
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Battery, body panels,bumpers, dashboard,
door panels, fuel system,interior and exterior trims,lighting systems, seats,
seatbelts, airbags, under
shieldsupholstery
Rotor blade
Housing
Extensive use of plasticcomposites in the
Boeing 787 Dreamliner
reduces weight, fuel consumptionand allows new design concepts.
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The consequence: A need of new High Temperature (HT) -Materials and relevant material data.
Higher pressurehigher mechanical
load
Need of material strength data
creep, stress rupture strength, creep rupture strength
Stress and creep rupture tests
Actual potential
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
5
Higher temperatureshigher thermical
load
Cost reductionless conservative
part dimensioning
optimized service
intervals
Tensile strength, strain limits, E-ModulusQuasi-static tests
Life time prediction with cyclic loads
Fatigue tests
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Actual potential
Messphysik order entry: Academia, Energy and Metal are themost dominant industries.
26%
4% 3%
Creep order entry by industry2008-2012
Academia
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DI Peter Ruchti (MSc.)
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1%
20%
46%
Academia
Automotive
Energy
Metal
Paper
Plastics
Textile
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Actual potential
8%
1%7%
2%
Home market
Rest of Europe
Creep order entry by regions2008-2012
Messphysik order entry: The European market makes up overhalf of the creep order entry. A quarter of the creep order entry
arises from the Asian market.
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DI Peter Ruchti (MSc.)
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46%
26%
11%
8% Rest of Europe
Asia without ChinaChina
USA
Russian Federation
Latin Amerika
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Agenda
Creep testing with Messphysik
Actual potential
Furnace and tem erature controller
Working principles metals
Working principles plastics / composites
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
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Customer projects on other materials
Customer projects on metals
Customer projects on plastics
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Direct Load Lever rm Spindle
Dead
Weight
Dead
Weight
Spring
Loaded
Single
Spindle
Dual
Spindle
Schematic
Working principles - metals
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DI Peter Ruchti (MSc.)
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Run duration > 10.000 h > 10.000 h > 10.000 h < 10.000 h < 10.000 h
Control
modeForce Force
Force, Stress,
Strain
Force, Stress,
Strain
Force, Stress,
Strain
Load strings
in one frame ~ 100 ~ 12 ~ 12 Multi 1
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Lever arm creep testers – schematic diagram 1l0 l1
F = W∗(l /l ) F
Working principles
Creep Testing with Messphysik - Base September 2012
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W
F = W∗(l0/l1) F
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± 0.05°
eendnd switchswitch
lloadoad cellcell
Lever arm creep testers – schematic diagram 2
Working principles
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
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F
s
Dead weight: f forceorce = const.= const. Spring load: f forceorce,, stress, strainstress, strain = const.= const.
W
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Working principles
0,05
limit switchlimit switch
loading and load control by gravity
automatic adjustment of lever arm atcreep of specimen
control parameter: balance of lever arm
application: creep test with constant load
Principle Creep Test: lever arm with dead weight
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
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W
t
F
F=F= constantconstant
12
100%
2%
According toweight distribution
application: creep test with constant load
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Working principles
Principle Creep Test: lever arm with preloaded spring
loading by preloaded spring
load controlling by controlling the
load cell signal
application: creep test
with constant load or loading blocks
load cell =load cell =
controlcontrol
channelchannel
extensometer =extensometer =
measurement measurement
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
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t
F
t
F
F/F/ == constantconstant F/F/ == bblocklock
13
100%
0,5%
stepless
with constant load or loading blocks
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Principle Creep Test: lever arm with preloaded spring
loading by preloaded spring
strain control by controlling the
Extensometer signal
application: relaxation test
Working principles
load cell =load cell =measurement measurement
extensometer =extensometer =controlcontrol
channelchannel
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
application: relaxation test
or other strain controlled tests
t
14
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Spindle-driven creep testers – schematic diagram
LoadLoad
cellcell
Working principles
LoadLoad
cellcell
Closed loop
control
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DI Peter Ruchti (MSc.)
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Single-spindle drive Dual-spindle drive
control
Closed loop
control
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Agenda
Creep testing with Messphysik
Actual potential
Furnace and tem erature controller
Working principles metals
Working principles plastics / composites
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
16
Customer projects on other materials
Customer projects on metals
Customer projects on plastics
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Direct Load Lever rm Spindle
Dead
Weight
Dead
Weight
Single
Spindle
Multi-
station
Schematic
Working principles – plastics and composites
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
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Run duration > 10.000 h > 10.000 h < 10.000 h < 10.000 h
Control
modeForce Force
Force, Stress,
Strain
Force, Stress,
Strain
Load strings
in one frame ~ 100 ~ 12 1 ~6
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LoadLoad
cellcell
LoadLoad
cellcell
LoadLoad
cellcell
LoadLoad
cellcell
LoadLoad
cellcell
LoadLoad
cellcell
Working principles – plastics and composites
1x environmental chamber
6x
6x
Multi-station creep testers – schematic diagram
Creep Testing with Messphysik - Base September 2012
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6x closedloop control
Multi-station creep testers
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The most dominant machine type with creep tests on plastics is themulti-station creep tester.
Working principles – plastics and composites
1 to 6 test axes per load frame
Central spindle with each test axis andindividual closed-loop-control
One temperature chamber for 1 to 6 test
axes
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
19
axes
Alternatively two temperature chambers in
one load frame (each for maximum 3 test
axes)
Non-contacting strain measurment
(recommended by testing standards)
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Strain measurement with Multiplexing – shematic diagramm
…
n-Specimenin field of view
of 1 camera*
Multiplexing of cameras
Camera fornon-contacting Extensometer
up to 12… …
Working principles – plastics and composites
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
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Multiplexing Controllerson 1 Master-PC
Multi-station
Master-PC
Load Lift
…
… * dependant on gage length, elongation anddistance between stations, Standard: 3-4 specimen
up to 256 Multiplex-PCs
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Strain measurement with Multiplexing – advantages
Accuracy of each station measurement + 0,01mm
Fixed cameras therefore no uncertainty due to
moving cameras
Continuous measurement from backside of the
testing system
Working principles – plastics and composites
Creep Testing with Messphysik - Base September 2012
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Loading of new specimens does not interrupt
measurement of other stations
Free definition of time schedule for strain
measurement
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Multistation Master PC with testXpert Multistation Software
Test monitoring with tree structure
e.g. automatic measuring of channels,
time, strain and temperature Detection of break/rupture
Data storage incl. continuation of
interrupted test
Working principles – plastics and composites
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
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Test analysis
Results acc. to ISO 899-1 and ISO
899-2, ASTM D 2990, e.g. strain rate,
creep strength, creep modulus
Statistics
Automated reporting
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Agenda
Creep testing with Messphysik
Actual potential
Furnace and tem erature controller
Working principles metals
Working principles plastics / composites
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
23
Customer projects on other materials
Customer projects on metals
Customer projects on plastics
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High temperature furnaceAn important component of the creep system
3-Zone furnace up to 1.200°C / 1.400°C
Precise temperature distribution by 3-zone-temperature-controller Internal Diameter: 100 mm, Heated length: 300 mm
Vertical positioning of furnace:
Furnace and Temperature Controller
Creep Testing with Messphysik - Base September 2012
DI Peter Ruchti (MSc.)
openings for load string, Thermocouples and Extensometers
(optional: side windows for optical strain measurement)
3 Thermocouples for furnace controller;
up to 3 couples for Temperature
control at the specimen
Light, thermal insulation material (free of asbestos)
Casing made of stainless steel
24
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The intelligent control-algorithm minimizes efforts whensetting the control parameters and ensures standard compliant
specimen temperatures without overshoots.
Automated settings withthe 3-channeltemperature controller
for specimentemperatures between
° °
Furnace and Temperature Controller
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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.
Timesaving andoptimized use ofspecimen because thecomplex empirical
determination of control-parameters is no longer
required
Temperature tolerancesaccording to ISO 204
und ASTM E 139
Screenshots
vorläufig
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The Zwick temperature controller is timesaving andflexible in use.
3-channel Controller (Eurotherm 2604)
Integrated, technical sophisticated control-algorithm for a
constant temperature deviation along specimen and toavoid temperature overshoots
Empirical determined control parameters for different
temperatures are no longer required
Furnace and Temperature Controller
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Not sensitive to different air flow conditions (openings, etc.)
Interface for 6 thermocouples
− 3 pcs. to control the specimen temperature
− 3 pcs. to measure the furnace temperature
Digital display of temperature
One RS 232 Interface to PC with 6 virtual channels
Stand Alone- or testXpert-operation possible
Can be used for different 3-zone-furnaces
26
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PIDPIDTemp_1Temp_1
The multi-channel control-algorithm controls thespecimen temperature precisely.
Furnace and Temperature Controller
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PIDPIDMaster Master PIDPIDTemp_2Temp_2
PIDPIDTemp_3Temp_3
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Even with lower test temperatures the specimen temperaturesstay within the temperature tolerances of +/-2K.
T e m p e r a t u
r e i n
C
Furnace temperature
Example: test at 80 C, function of specimen and furnace temperatures
Furnace and Temperature Controller
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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Test time in h
T e m p e r a t u
r e i n Furnace temperature
Specimen temperture
1,6
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Also with high furnace temperatures, temperature tolerances areattained quickly without overshoots.Example: test at 1.000°C, function of specimen and furnace temperatures
° C
1000
Furnace and Temperature Controller
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T e m p e r a t u r e i
Test time in h
850
900
950
1,0 1,2 1,4 1,6 1,8
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The flexible control of the furnace temperature enables precisetemperature blocks on the specimen.
T e m p e r a t u r e i n
C
Example: test with temperature blocks of 5 C
Furnace and Temperature Controller
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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T e m p e r a t u r e i n
Test time in h
95
100
105
110
1 2 3 4 5
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Optimized heating parameters make short heat-up times possible.Therefore higher specimen through-puts can be achieved.
° C
Example: When mounting a specimen in a preheated furnace
further warm up times are reduced.
Opening of pre-heated furnace =
interruption ofcontrolling
Furnace and Temperature Controller
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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T e m p e r a t u r e i
Test time in min
Closing of partly cooleddown furnace
= restart of controlling
Time interval of specimen replacement
Due to the reduction, theheat-up time comes up to37 minutes
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Agenda
Creep testing with Messphysik
Actual potential
Furnace and tem erature controller
Working principles metals
Working principles plastics / composites
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
33
Customer projects on other materials
Customer projects on metals
Customer projects on plastics
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Customer projects on metals
Institute of aviation materials, Russia
Type of Test: High Temperature Tensile Creep Test
Testing Machine: Kappa 50 SS
Kappa 50 DS
Applied Standard: ASTM E 139
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
34
Specimen Types: Flat, threaded head (M10/Ø8 / M14/Ø10)
Environment: Elevated temperature up to +1.200°C
Strain: Creep test with strain measurement on specimen
Customer specific feature: Axial- & Transversal strain measurement
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Customer projects on metals
Institute of aviation materials, Russia
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Customer projects on metals
Institute of aviation materials, Russia
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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Type of Test: High Temperature Creep Crack Growth Test
Testing Machine: Kappa 50 SS
Applied Standard: ASTM E 1457
Specimen Types: CT-Specimen
Atomic Research Institute, India
Customer projects on metals
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
37
nv ronmen : m en an e eva e empera ure up o .
Strain: Measurement of load line deflection with
rod-in-tube extensometer, measurement
of creep crack growth with DCPD method
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Atomic Research Institute, India
Customer projects on metals
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Atomic Research Institute, India
Customer projects on metals
Measurement of creep crackgrowth with DCPD-Connection
Measurement of
load line deflection
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Power supply
Output signal
(potential drop)
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Customer projects on metals
D i s p l a c e m e n t i n m m
S t a n d
a r d f o r c e i n N
Load line displacement Standard force
In a single test both load line displacement and crack size ismeasured. Example: CCG test with CT-specimen at 5.985N and 700 C
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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D i s p l a c e m e n t i n m m
S t a n d
a r d f o r c e i n N
Creep time in h
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In a single test both load line displacement and crack size ismeasured. Example: CCG test with CT-specimen at 5.985N and 700 C
Customer projects on metals
Crack size Force
S t a n d a
r d f o r c e i n N
C r a c k
s i z e i n m m
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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S t a n d a
r d f o r c e i n N
C r a c k
s i z e i n m m
Creep time in h
C
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Nuclear Research Center, France
Type of Test: High Temperature Tensile Creep Test
Testing Machine: Kappa 50 DS
Applied Standard: Customer specific
Specimen Types: Material: zirconium
Flat, round and tubular specimen,
Customer projects on metals
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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(coupling by Swagelock clamping)
Environment: Ambient and elevated temperature up to +600°C
Strain: Optical measurement of axial strain and
reduction in width
Customer specific feature: Tunnel between Extensometer and HT-furnace 2
optical windows in HT-furnace
Test Results: Creep Curve
C t j t t l
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Nuclear Research Center, France
Customer projects on metals
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C t j t t l
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Nuclear Research Center, France
Customer projects on metals
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Customer projects on metals
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The axial and the transverse strain is measured contactlessunder high temperature.Example: Start of creep test at 450°C
Customer projects on metals
0.06
0.08
0.06
0.08
m m m
dL/t db/t
0,06
0,08
0,06
0,08
Creep Testing with Messphysik - Base September 2012DI Peter Ruchti (MSc.)
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0 2 4 6 8 10
0.00
0.02
0.04
0.00
0.02
0.04
Test time in h
S t r
a i n i n m
C h a n g e i n w i d t h i
C h a n g e
i n
w i d t h i n
m
S t r a i n
i n
Test time in hours4 106
0,00
0
0,02
2 8
0,00
0,02
C t j t t l
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Customer projects on metals
Type of Test: Strain creep test
Testing Machine: Kappa 50 LA spring
Applied Standard: ASTM F519
Specimen Types: Round, threaded head
Landing Gear Company, Netherlands
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Test time: up to 200h Customer specific feature: 4 specimen in series in the testing axis
C t j t t l
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Customer projects on metals
Landing Gear Company, Netherlands
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Customer projects on metals
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Customer projects on metals
Landing Gear Company, NetherlandsTest process to determine hydrogen embrittlement acc. to ASTM F519
1. Tensile testing to determine breaking strength
2. Creep testing with 75% of breaking strengtha. All 4 specimen resist the test of 200h –> no hydrogen embrittlement of
specimen and specimen surface treating
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. -
200h of total test time is reached. Then increase of force in 5%-steps (2htest time for each step) until the force has reached 90%.
2h
2h80 %
2h 85%
3 specimen4 specimen
time
force
75 %
t = x t = 200-x
t = 200
90%
t = 206
Customer projects on metals
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Atomic Research Centre, India Type of Test: Creep, relaxation,
user-programmable loading cycles
“fracture toughness”
Testing Machine: Kappa 100 DS
Applied Standard: ASTM E 139, ISO 204
ASTM E 399, ISO 12135
Customer projects on metals
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Specimen Types: metal and ceramics specimens
Environment: metal up to +1.200°C
ceramics up to +1.600°C
Loading: constant stress creep tests
Customer specific feature: 1 furnace up to +1.200°C and
1 furnace up to +1.600°C
This furnaces are alternately pivoted
Customer projects on metals
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Creep test machine for multiple materials, environments andapplications.
Customer projects on metals
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Customer projects on metals
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Customer projects on metals
Tensile TestBending Test
Atomic Research Centre, IndiaTests at ambient temperature
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Customer projects on metals
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Customer projects on metals
Creep Tensile Test Creep Crack Growth
Atomic Research Centre, IndiaTests at high temperature
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Customer projects on metals
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Customer projects on metals
The true strain rate can be automatically controlled.With compression tests the crosshead speed is decreasing.Example: Compression test with true strain rate of 0,1% / sec
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D e f o r m a t i o
n i n %
Customer projects on metals
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Customer projects on metals
Very low traverse speeds are possible.Example: 1 µm / hour
60
80
100
m n µ m
dL/t
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0 2000 4000 6000
0
20
40
Test time in min
S
t r a i n i n µ
S t r a i n i
Test time in min
Customer projects on metals
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Customer projects on metals
Compliance to a corridor of +/- 0,1% at a traverse-speed of 1µm/h.
s t r a i n i n µ m
Nominal strain /t
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Test time in h
N o m
i n a l
Agenda
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Creep testing with Messphysik
Actual potential
Furnace and tem erature controller
Working principles metals
Working principles plastics / composites
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Customer projects on other materials
Customer projects on metals
Customer projects on plastics
Customer projects on plastics
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p j p
Specialty chemicals group, Germany
Type of Test: Creep and relaxation tests and
user-programmed stress cycles
Testing Machine: 2x Kappa 50 SS – 5 x 10 kN Applied Standard: ISO 527-2 Type 1A
Specimen Types: Tensile specimens of plastic
Creep Testing with Messphysik Feber 2012
DI Peter Ruchti (MSc.)
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Tensile specimens according to ISO 527-2 Type 1A
Tensile specimens with shoulder width 35 mm
Environment: Ambient temperature up to + 200°C
Loading: Motor via ball screw drive
Strain: Optical strain measurement
Customer specific feature: 5 load trains together in 1 temperature chamber
Distance of the test axes to each other: 105 mm
Customer projects on plastics
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Specialty chemicals group, Germany
Creep Testing with Messphysik Feber 2012
DI Peter Ruchti (MSc.)
5858
Customer projects on plastics
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Specialty chemicals group, Germany
Creep Testing with Messphysik Feber 2012
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Customer projects on plastics
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Creep curve easily displayed with testXpert – determination of
minimum creep speed and three creep phases
Example: Tensile Creep Test at 60 C and 16 MPa
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6060
Customer projects on plastics
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Specialty chemicals group, Germany
Creep Testing with Messphysik Feber 2012
DI Peter Ruchti (MSc.)
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Front view Rear view
Agenda
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Creep testing with Messphysik
Actual potential
Furnace and tem erature controller
Working principles metals
Working principles plastics / composites
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Customer projects on other materials
Customer projects on metals
Customer projects on plastics
Customer projects on other materials
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Technical University, Austria: ceramics
Type of Test: Creep compression tests
Testing Machine: Kappa 100 SS
Specimen Types: Ø35mm, h=70mm
Environment: Elevated temperature up to + 1.600°C
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63
.
Strain: strain measurement from two opposing
positions, max. compression 5-8%
Customer specific feature: Tests on refractory materials
Customer projects on other materials
8/18/2019 Creep Seminar Ruchti
64/66
Technical University, Austria: ceramics
Creep Testing with Messphysik – diverse Materials September 2012
DI Peter Ruchti (MSc.)
64
Customer projects on other materials
8/18/2019 Creep Seminar Ruchti
65/66
The two-sided measurement of the compression is displayed
in testXpert both separately and averaged.Example: Test at 1.500 °C and konstant force of 7.500 N
Creep Testing with Messphysik – diverse Materials September 2012
DI Peter Ruchti (MSc.)
65
Customer projects on other materials
8/18/2019 Creep Seminar Ruchti
66/66
Technical University, Austria: creep tensile tests on refractory
material
water cooling input
water cooling output
watercooling
loadstring
alignment unit
Creep Testing with Messphysik – diverse Materials September 2012
DI Peter Ruchti (MSc.)
adhesive area
6666
adhesive area
water cooling output
water cooling input
water cooling output
refractory material
heated zone
adhesive area
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