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Testing of Castings and Forgings

Castings and forgings are primarily used in the automotive industry and in aerospace and power plant construction. Casting technology allows complex parts to be manufactured cost effectively, with an ever-increasing use of light metal castings to reduce weight, especially in engine manufacture. For extreme demands regarding strength, pressure or impact loading, forged components are used, as are crankshafts and connecting rods in engines, and generator and turbine shafts in power plants.

Tensile tests Hardness tests Fatigue tests Metals brochure

Tensile tests on castings and forgings

Cast and forged components are produced in a way that the smallest degree of further processing is needed to make them fulfill their intended purpose.

For tensile tests on castings and forgings, this means either removing specimens from specified locations or using the component as a whole to determine tensile strength. Testing the whole component requires high test loads and component-specific gripping arrangements and fastenings, while component geometries often result in the production of specimens with small final dimensions. For small round specimens, ZwickRoell provides special specimen grips which are easy to handle and allow the use of automatic extensometers; complete components are tested with the help of a comprehensive accessory and option package.

Tensile test on metals
ISO 6892-1
to Tensile test on metals
Tensile test on metals
to Tensile test on metals
Tensile test on metals at elevated temperature
ISO 6892-2
to Tensile test on metals at elevated temperature

Products for tensile tests on castings and forgings

Hardness tests on castings and forgings

The hardness value is an important characteristic when monitoring the manufacturing process for cast and forged components. The Brinell method with high test forces is often used on components in order to obtain a stable average value over the different microstructural components through large indentations.

The hardness of microstructural components is determined on specimen sections using the Vickers micro-hardness testing method. ZwickRoell’s operator-friendly Brinell hardness testing machines with automatic indentation measurement up to a load level of 3,000 (29,000 N) are complemented by a comprehensive micro Vickers instrument portfolio, including fully automated systems.

Rockwell hardness test metals
ISO 6508, ASTM E18
to Rockwell hardness test metals
Vickers hardness testing metals
ISO 6507, ASTM E384
to Vickers hardness testing metals
Vickers & Knoop hardness metals
to Vickers & Knoop hardness metals
Brinell hardness test metals
ISO 6506, ASTM E10
to Brinell hardness test metals

Products for hardness tests on castings and forgings

Fatigue tests on castings and forgings

In practice, where castings and forgings are concerned, reliable estimation of durability is of particular importance. This requires single specimens and, importantly, entire components such as forged connecting rods, to be tested intensively under cyclic loading.

These high-cycle fatigue tests are reproduced, in resonance testing machines for example, and components are stressed with cyclic loads up to 600 kN at frequencies up to 285 Hz. ZwickRoell’s range of highly efficient, cost-effective resonance testing machines is now also backed by a greatly expanded servohydraulic testing machine portfolio.

High Cycle Fatigue Test / S-N Test
DIN 50100
to High Cycle Fatigue Test / S-N Test
Calculated service life
to Durability

Products for fatigue tests on castings and forgings

Additional tests for castings and forgings

Notched Charpy impact test metals
ISO 148-1
to Notched Charpy impact test metals
Charpy and Izod notched impact test metals
to Charpy and Izod notched impact test metals
Creep Test
to Creep Test
Biaxial Test
to Biaxial Test

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