High-temperature testing system

In applications such as engine design, power plant design, powertrains, and chemical plants, the material behavior under increased temperatures up to approx. 2,000°C and higher are of vital importance. For these tests, the ZwickRoell Group offers modular standard solutions for a temperature range of-80°C to 1,600°C and customized testing solutions up to a temperature of 2,000°C.

ZwickRoell's complete solutions for high-temperature are based on the proven load frame concept of the AllroundLine. The flexible and modular load frame design in conjunction with an array of high-temperature components enable the configuration of individual testing systems that are optimally matched to the testing requirements of our customers.

Modularity of the High-Temperature Testing Systems

In order to meet various standards requirements and customer requirements for high-temperature testing, ZwickRoell offers modular high-temperature testing systems for quasi-static tensile, compression, and flexure tests. The optimal system combination is achieved when the customer-specific requirements such as the test temperature, the specimen shape to be tested, specimen geometry, and specimen size as well as the components used in the testing system work together. 

The key components in high-temperature testing systems are:

Extensometers

Depending on the specimen material and selected heating system, either contact or non-contact extensometers will be better suited for the high-temperature test ZwickRoell addresses the various challenges in extension measurement by providing a large selection of extensometers. Problems such as hindered contact to the specimen due to tight access points to the heating system, temperature sensitive sensors, insufficient light conditions or air currents become a thing of the past.

Heating systems

The high-temperature test is performed at different temperatures depending on the material. Plastics or composites are already tested at 250°C for temperature resistance. For metals and other high-temperature resistant materials, temperatures that far exceed 1,000°C are relevant. Due the large selection of various heating systems, ZwickRoell high-temperature testing systems can reach any temperature up to 2,000°C.

Switching and control system

Precise control of the specimen temperature is the foundation for each high-temperature test. With ZwickRoell’s switching and control system for automatic and user-independent control of the specimen temperature, standard-compliant temperature tolerance can be maintained reliably without overshooting and without having to determine the control parameters empirically.

Specimen temperature measurement

The requirements of temperature measurement in high-temperature testing are very strict and can only be achieved with suitable thermocouples and reliable calibration of the entire temperature measurement chain. The most used thermocouples in high-temperature testing are Type N and S. However, under certain circumstances alternative types may also be used.

Load string

Depending on the type of test and the test temperature, ZwickRoell high-temperature testing systems are equipped with metallic or ceramic load strings. Alignment fixtures and self-aligning load strings are used to achieve optimal alignment.

  • Tensile tests: Self-aligning load string, metal or ceramic
  • Compression tests: Self-aligning load strings made of metal with reversal cage or fixed load string in ceramic version
  • Flexure test: Fixed load string, ceramic

Specimen grips

Specimen grips in high-temperature testing must not only ensure a secure grip on the specimen at all temperatures but also withstand the thermal and mechanical loading. Depending on the specimen shape and specimen material, specimen grips come in different versions and materials in order to provide maximum flexibility of ZwickRoell high-temperature testing systems.

Standard High-Temperature System Combinations

The array of load frames, heating systems, specimen temperature measuring devices, extensometers, and specimen adapters allow for numerous individual system combinations.

The below-listed example system combinations provide some insight into the modularity of ZwickRoell high-temperature testing systems.

Advantages and features

  • ZwickRoell offers an array of solutions. with a minimum temperature of 200°C and a maximum temperature of 2,000 °C
  • Depending on the materials to be tested, 1-, 2-, or 3-zone furnaces with air, vacuum, or inert gas environments are available.
  • ZwickRoell solutions feature optimal coordination of furnaces including temperature controllers, the appropriate specimen grips for tensile and flexure tests, and the respective contact-type and non-contact extensometers.
  • The high-temperature furnaces and extensometers are provided with swivel units, allowing comfortable, convenient operation of the testing machine, which can then be used for room-temperature testing with practically no reconfiguration
  • Using a centrally divided hinged furnace enables the pull-rods in use to be inserted and withdrawn easily via a quick-change system.
  • A specimen temperature measuring device with up to three thermocouples is used for direct temperature measurement on the specimen, ensuring standard-compliant testing at temperature.

System combination 1

This testing solution is often used in quality control and is ideal for testing similar specimen geometries and sizes. The fixed specimen temperature measuring device not only enables easy operation, it also creates the foundation for reliable and repeatable test results.

System overview:

  • Table-top testing machine with adjustable setting of the working height for optimal ergonomics
  • High-temperature furnace in a temperature range of 200°C to 1,250°C
  • Standard-compliant and user-independent temperature controller for precise specimen temperature control
  • Specimen temperature measurement with fixed distance between the thermocouples for similar specimen geometries and sizes
  • High-temperature load string
  • Measurement of specimen strain with non-contact or contact-type extensometers
  • Proven testControl II measurement and control electronics
  • Force range up to 150 kN

System combination 2

Various specimen sizes and geometries require testing systems that are flexible but still deliver reliable test results. This system combination, which is often used in research institutes and universities is, therefore, ideal and allows flexure and compression tests to be performed in addition to tensile tests due to the variable specimen temperature measuring device.

System overview:

  • Table-top testing machine with working height that can be adjusted for optimal ergonomics
  • High-temperature furnace with height-adjustable positioning in a temperature range of 200°C to 1,250°C
  • Furnace swivel unit enables tests even at room temperature
  • Standard-compliant and user-independent temperature controller for precise specimen temperature control
  • Specimen temperature measurement with variable distance between thermocouples for various specimen geometries and sizes
  • Variable furnace openings for various mounting options for extensometers and temperature measuring devices
  • High-temperature load string
  • Measurement of specimen strain with non-contact or contact-type extensometers
  • Proven testControl II measurement and control electronics
  • Force range up to 150 kN

System combination 3

This extremely flexible testing solution will meet the strict requirements of testing service providers since it covers an expanded force range in addition to the wide array of specimens and tests.

System overview:

  • Floor-standing testing machines with easy and quick adjustment of the working height
  • High-temperature furnace with height-adjustable positioning in a temperature range of 200°C to 1,250°C
  • Furnace swivel unit enables tests even at room temperature
  • Also available with a lateral work area to prevent the need for modifications and to allow easy switching between room and high-temperature tests
  • Standard-compliant and user-independent temperature controller for precise specimen temperature control
  • Specimen temperature measurement with variable distance between thermocouples for various specimen geometries and sizes
  • Specimen temperature measurement with variable distance between thermocouples for various specimen geometries and sizes
  • High-temperature load string
  • Measurement of specimen strain with non-contact or contact-type extensometers
  • Proven testControl II measurement and control electronics
  • Wide force range up to 250 kN, second load cell for small force ranges can optionally be used

Franchini Acciai uses modular testing system for tests in ambient and high temperatures

Franchini Acciai is a company founded in 1968 specialized in forging, heat treatment and machining of carbon, alloy and stainless steel. It has pursued a policy of continuous technological development and plant installation expansion, thus achieving a leading position among forgemasters.
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