Testing Machines and

Systems 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 ................................................................................................................................ 6
3.1 Heavy Plate............................................................................................................................................. 7
3.2 Strip and Sheet ...................................................................................................................................... 11
3.3 Thin Sheets ............................................................................................................................................ 13
3.4 Bars and Rods ....................................................................................................................................... 16
3.5 Section and Reinforcing Steel ................................................................................................................. 18
3.6 Wire and Cable ...................................................................................................................................... 21
3.7 Pipes ..................................................................................................................................................... 23
3.8 Castings and Forgings ............................................................................................................................ 25
3.9 Fasteners ............................................................................................................................................... 26
4 Quasi-Static Materials Testing: Products and Services ..................................................................................... 28
4.1 Material Testing Machines....................................................................................................................... 28
4.2 Drives for Quasi-Static Testing Situations ................................................................................................. 30
4.3 Sheet Metal Testing Machines ................................................................................................................ 33
4.4 Hardness Testing Machines and Instruments ........................................................................................... 34
4.5 Measurement and Control Electronics ..................................................................................................... 38
4.6 testXpert

II ............................................................................................................................................ 39
4.7 Load Cells .............................................................................................................................................. 42
4.8 Specimen Grips...................................................................................................................................... 43
4.9 Extensometers ....................................................................................................................................... 45
4.10 High-temperature Testing Accessories .................................................................................................... 49
4.11 Creep Test ............................................................................................................................................. 50
4.12 Robotic Testing Systems......................................................................................................................... 51
4.13 Specimen Preperation ............................................................................................................................ 54
5 Fatigue Strength and Dynamic Strength Testing: Products and Services .......................................................... 55
5.1 Fatigue Testing Machines ....................................................................................................................... 55
5.2 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 overview
of devices, machines and systems of
the Zwick Roell AG for the testing of
metals in the corresponding indus-
tries, research and development,
production, quality assucrance, test
institutes and training centers.
As such this represents only a part
of our comprehensive overall pro-
gram.
3
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 Austrian
company Messphysik (2007) the
know-how of the Zwick Roell AG in
the field of force and elongation
measurement has been safed and
enriched.
Zwick has many years of experi-
ence, combined with a multitude of
supplied systems, and this experi-
ence is continuously supplemented
by constant communication with
customers. On this solid base the
company supplies a wide range of
high-performance products from
the economical standard quality
control machine up to customised
solutions designs for specific test
requirements. Modern mechanics,
high-performance electronics and
the application-oriented software are
the prerequisite for the versatility and
the high intelligence of these mo-
dern testing machines and systems.
The services of the Zwick Roell AG
go far beyond the supply of prod-
ucts. In 1994 the company received
its certification ISO 9001 accredited
helping to guarantee a consistently
high product and service quality.
With its accredited calibration lab-
oratories, the companies of the
Zwick Roell AG are able to verify and
calibrate test systems and to issue
internationally recognized certificates.
1 The Zwick Roell AG
more than a century
of experience in
materials testing
Mechanical-technological testing is
one of the oldest disciplines of
materials testing. As early as in the
15
th
and 16
th
century, Leonardo da
Vinci and Galileo Galilei were already
considering the flexural stressing and
elastic behaviour of materials.
In the course of time further know-
ledge was obtained. In the middle of
the 18
th
century the first testing ma-
chines finally appeared in France.
Since 1920 the company Roell &
Korthaus was involved in the materials
testing business. In 1937 Zwick built
its first testing machines and sys-
tems for mechanical testing of mate-
rials, and many years prior to that in
1876, a Professor Seger had founded
a chemical laboratory as part of a
scientific technological consulting
company for non-metallic materials.
During the 20
th
century the present
company, Toni Technik, has evolved
from these origins and is now con-
sidered a leading expert in test
systems for building materials. MFL
(Mohr & Federhaff) a company that
was founded in 1870 became part
of the Zwick Roell group and interest-
ingly, Carl Benz (of Mercedes Benz
fame) was one of their employees.
Since 1992, these companies have
formed the Zwick Roell group, and in
July 2001, the company group was
converted into a stock corpo-ration:
the Zwick Roell AG. Part of this
stock corporation are the companies
Zwick, Toni Technik, Indentec Ltd.,
and since may 2002 Acmel Labo.
These companies supply an extensive
program for materials, component,
and functional tests from the man-
ually operated hardness tester up to
a complex robotic test systems for
the twenty-four-seven production
control.
4
2 Metals Use and
Properties
The properties of metallic materials
metals and metal alloys cover a
very broad spectrum. The distinction
between function and structure also
applies to materials; examples of
structural and construction materials
include materials for machine and
plant building, precision engineering
and civil engineering, while functional
materials are used in areas such as
electrical engineering, electronics
and media technology.
With construction materials the
emphasis is on mechanical proper-
ties such as strength, rigidity
(elasticity) and ductility (plasticity) at
working temperature. These
characteristics are the main influ-
ence in testing-machine design
(maximum required test load for load
frames and load cells) and equip-
ment (high-resolution extensometers
for Youngs Modulus determination).
As an illustration, steel under
mechanical loading displays very
high stiffness right from the beginning
of the test unlike rubber, for
example. This results in large load
increases for very small deforma-
tions, often less than a hairsbreadth.
These deformations are elastic and
decrease again with load reduction.
Only when the load is further
increased is a plastic (i.e. perma-
nent) deformation superimposed on
the elastic deformation.
Specimens of very brittle materials
(such as cast iron) or soft steels at
low temperatures fracture without
warning on reaching cohesive
strength (i.e. with no prior necking).
Fig. 1: Load-extension curve of sheet-steel tensile specimen (upper) and enlarged view of
the area until just after 0.2 % proof stress (lower)
By contrast, local stiffness in tough
materials decreases sharply after the
elastic limit has been exceeded and
can even reach values of zero or
less (increase in deformation without
load increase or even with load
reduction).
The load-extension curve of a steel-
sheet tensile specimen (gage length
L
0
= 80 mm) illustrates very well the
change in stiffness as deformation
increases.
Table: Comparison of Specific Material Properties
Material properties Metals Concrete Plastic mat.
(without extreme values) (non-reinforc.)
Tensile and compression
strength [MPa] 100 ... 2000 200 ... 500 20 ... 160
Youngs Modulus [GPa] 70 ... 210 15 ... 40 0,06 ... 6
Density (specific weigth) [g/cm] 2,7 ... 7,8 2,1 ... 2,4 1 ... 2
5
Fig. 1: Stress-strain/crosshead travel curve of a tensile specimen made of steel sheet (tested
with a Zwick Z100 materials testing machine with hydraulic specimen grips)
The purely elastic strain up to the
elasticity limit is only approx. 0.06 %
(approx. 50 m); by contrast the
plastic strain up to failure is almost
32 % (approx. 26 mm) more than
500 times greater! This imposes
particular requirements on the
extensometer used in the same test
to determine the slope of the straight
line in Hookes Law (Youngs
Modulus), the proof stress, the strain
at maximum force and the strain at
break - high resolution and large
displacement measurement are es-
sential. Additionally, the measurement
system must not be damaged by a
sudden specimen break.
It is not only the specimen that
deforms under the influence of the
test load. All components located in
the load train of the testing machine
(load frame, load cell, specimen grips
and the parts of the specimen out-
side the gage length) also deform
but only elastically. For specimens
with high stiffness, the elastic defor-
mation of the testing machine tends
to be significantly greater (up to ten
times) than that of the specimen.
Indirect strain measurement via
crosshead or piston travel is there-
fore much too imprecise to measure
the slope of Hookes lines and the
corresponding proof stress.
The crosshead or piston travel of the
testing machine is distributed
between specimen and machine
deformation according to the ratio of
specimen stiffness to machine
stiffness. The deformation rate is
thus not only dependent on cross-
head or piston speed, but also on
the specimen (stiffness, geometry)
and on machine configuration.
Test results, particularly for softer
materials, are affected by defor-
mation rate, so comparability of test
results from specimens of different
dimensions or between different
machines can only be guaranteed if
the crosshead or piston speed is set
or regulated (in accordance with the
measured load or deformation) to
allow comparable deformation rates.
Testing Standards Essential
for Comparable Results
A fundamental role of testing
standards lies in creating the same
conditions for specimen and test
sequence, regardless of when,
where and what is being tested. The
international standards, which are
increasingly replacing national
standards, are an essential step to
further improving the comparability of
test results. The tables from page 67
onwards summarize the principal na-
tional and international standards
used today for testing metals.
As a rule the standards are reviewed
every five years and also amended if
applications to do so have been
received and a majority of the
standards committee are in favor.
Zwick Roell employees are active on
several standards committees,
bringing the specialist knowledge
and experience of a testing machine
manufacturer to the table and at the
same time keeping their knowledge
up to date for product development
and specialist advice to customers.
6
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 and
reinforcing 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)

3 Tests in the Metal Industry
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7
3.1 Heavy Plate
Heavy plates are steel sheets with a
width of up to four meters and a
thickness of at least five millimeters,
up to approx. 250 mm. They are
used principally in the construction
industry, for heavy plant and cranes,
in shipbuilding, for offshore drilling
platforms and for large-diameter,
thick-walled pipes.
Hardness Testing
Hardness testing to Brinell up to test
loads of 29,000 N can be performed
with ZHU topLine series hardness
testing machines. This range features
state-of-the-art technology, employ-
ing a zoom lens, CCD camera and
LCD display, with high reproducibility
ensured by the automatic test
sequence and closed-loop tech-
nology. For Brinell tests the ringlight
option offers a further increase in
measurement accuracy. Zwick also
has instruments available for portable
hardness testing and for all hardness
testing methods to Vickers (p. 34
onwards).
Tensile Test
Tensile specimens are removed from
heavy plate in such a way that the
sheet thickness is retained as speci-
men thickness as far as possible.
Specimens have a correspondingly
large cross-section, the parallel length
being produced by milling. The tensile
test material properties are therefore
determined over a large volume and
the influences of specimen production
minimized. Zwicks wide range of
standard testing systems up to 2500
kN provide high-accuracy testing
under high loads; our hydraulic
specimen grips ensure that perfect
clamping and positioning of specimens
are maintained during tests. Strain
measurement in most cases is via a
Macro digital extensometer, offering a
high degree of robustness its
sensor arms remain on the specimen
until failure. It also features easy
operation; the sensor arms are
applied automatically at the start of
the test and can be placed in a safe
idle position at the end. The high
measurement accuracy (up to ISO
9513 Class 0.5) is not affected by
oxide layers and gage length (L
0
)
adjustment can be performed
automatically via the testing software.
Fig. 1: Heavy plate specimen with macro
extensometer
Fig. 2: ZHU3000topLine Universal hardness
testing machine
8
Robotic Testing Systems for
Tensile Tests
The safe, reliable and precise
handling of heavy specimens places
considerable demands on the
operator and the operating system.
Zwicks robotic testing solutions
completely automate the testing
process while relieving the load on
operators, minimizing operator errors
and increasing operational safety
and reliability. Under our robotic
testing concept, the specimens for
testing are sorted into magazines
manually, but from this point
everything takes place automatically
up to sorting of the specimen
remains for inspection if necessary.
Additional measuring devices can be
integrated into the sequence as
required, in particular Zwicks cross-
section measuring device with four
independent, automatically applied
measuring transducers for precise
cross-sectional area determination.
Fig. 2: Heavy plate specimen in automatic
cross-section measuring device (QMG)
Fig. 1: Automated tensile testing of heavy plates (roboTest B)
9
Fig. 1: CT specimen in Vibrophore (HFP)
Fig. 2: SENB specimen in Vibrophore (HFP)
Fracture Mechanics
K
Ic
Determination
Fracture toughness K
Ic
is an impor-
tant material property for metallic
materials in safety-related applica-
tions such as aircraft construction,
power-station building and automobi-
le manufacturing and is determined
using a specimen into which an
artificial crack has been introduced.
The specimen is loaded until failure
and the fracture toughness K
Ic
is
determined from the load-deformation
curve and the crack length. Details
of the test procedure are contained
in the relevant standard (ASTM E 399)
and the two-stage test can be per-
formed very efficiently using Zwick
Vibrophores (HFP). Crack formation
in the specimen is instigated by the
mechanically produced notch
followed by cyclic loading. The high
frequency used allows rapid
generation of a defined crack (pre-
cracking) and the process is highly
reproducible, thanks to the high
sensitivity of the resonant frequency
to crack formation. The specimen
geometry most frequently used is
illustrated in Fig. 1; the specimen is
known as a CT (Compact Tension)
specimen. The load is applied
through pins inserted into holes in
the specimen, giving a mixed tensile
and flexure loading. Flexure speci-
mens (known as SENB specimens,
Fig. 2) are also used. While the
testing method is simpler for the
flexure specimen than the CT
specimen, the required specimen
volume is significantly greater. This is
clearly shown in the illustrations.
10
Charpy Impact Test
Notched impact strength is an im-
portant characteristic for applications
in pipeline construction and ship-
building and can be determined with
Charpy specimens in pendulum
impact testers. The standardized
notched specimens are inserted by
hand, by means of simple feeding
devices, or using robotic systems
and impacted with energies up to
750 J. Zwick supplies temperature
conditioning systems for correct
conditioning of specimens down to
-180 C. Under the Machinery
Directive, pendulum impact tester
operation is subject to strict safety
requirements, which are easily met
by Zwicks safety housing and
sophisticated safety technology.
Pellini Drop-Weight Test
Zwick Pellini drop-weight testers are
used to investigate the influences of
a weld on crack formation in steel
materials. Conditioned standardized
specimens are impacted up to
1650 J, with manual optical
evaluation of crack formation or
break, depending on the specimen
temperature selected.
Fig. 1: RKP 450 pendulum impact tester (Inset: anvil)
Fig. 2: Pellini drop-weight tester
Additional Tests for Heavy
Plates:
Tensile test at elevated
temperature
Creep tests
Flexure and compression tests
Shear tests/weld seam tests
Fatigue tests
Rotating bar bending fatigue tests
11
3.2 Strip and Sheet
Strip refers to steel and non-ferrous
products which are rolled into coils,
e.g. hot-rolled strip, which is used as
primary material for cold-rolled
sheets. Hot-rolled strip is produced
in thicknesses up to 15 mm and in
widths up to 2200 mm. Hot-rolled
plate is sheets cut out of hot-rolled
strip and is up to 15 mm thick and
up to 2000 mm wide.
Tensile Tests with r- and n-Value
Determination
r- and n-values are often also deter-
mined in tensile tests in order to
characterize forming properties; the
n-value describes the work
hardening increase in stress
during plastic deformation up to uni-
form elongation, while the r-value
describes the vertical anisotropy. The
n-value is determined from the
tensile stress data and strain values;
for the r-value the transverse strain
on the tensile specimen is addition-
ally measured. Tensile specimens
are taken from the strip or sheet at
set angles to the rolling direction.
One factor affecting the r-value is
the rolling direction. The sheet
thickness is retained as specimen
thickness, while the parallel length is
produced by milling or punching plus
finishing.
Zwick supplies a wide range of
standard testing systems for deter-
mining material properties from
tensile tests; these systems provide
high-precision testing under high
loads. Our comprehensive range of
axial and transverse strain extenso-
meters provide the optimum combi-
nation according to the customers
requirements and testing conditions,
e.g. a Macro digital extensometer
combined with an optical transverse
strain extensometer. This combination
is noted for robustness and a high
level of automation plus easy speci-
men handling. Both extensometers
measure up to specimen break.
Biaxial Tensile Test
The biaxial tensile test is used to
determine the deformation charac-
teristics of materials. This test is
used primarily for research and
development as it allows defined
stress values in the intersection area
of the specimen to be set up and
investigated. These testing machines
are produced to customers require-
ments. Strain measurement is
performed using non-contact
extensometry in most cases and
Zwick provides several solutions for
this; measurement of strain distri-
bution is available via collaboration
with Zwicks specialist partners.
Fig 1: Traverse strain extensometer: videoXtens; an axial strain extensometer: macro Fig 2: Biaxial tensile test
12
3-Point Flexure Test
The 3-point flexure test is used for
determining flexural properties and
for visual assessment of the bending
edge, an important aspect of the
flexure test being visual evaluation of
the behavior of weld seams. Zwicks
range of flexure test kit options
combined with adaptations to
existing specimen holders provides
an ideal solution.
High-temperature Tests
In applications such as engine manu-
facture, power station construction
and chemical plants, material be-
havior at elevated temperatures (up
to approx. 1200 C) is of vital impor-
tance, calling for high-temperature
tensile testing and, to a lesser extent,
flexure testing. Zwicks solutions for
these tests comprise temperature-
controlled furnaces, specimen pull-
rods, high-temperature strain
measurement and other essential
accessories for integration into Zwick
testing machines.
Fig. 3: High-temperature flexure test in
furnace
Fig. 1: 3-point flexure test kit for metal strip
Fig. 2: Hot tensile test in high-temperature
furnace
Additional Tests on Strip and
Sheet:
Ductility tests
Shear tests/weld seam tests
Creep tests
Fatigue tests
High-speed tests
Charpy impact tests
Automated testing
13
3.3 Thin Sheets
Thin sheets and foils are the last
step in the production of flat
products. Thin sheets are between
0.35 and 3.0 mm thick, whereas
foils are typically less than 60 m.
Applications for these flat products
are many and varied and the range
of tests is correspondingly wide. Only
a few are mentioned in this
brochure.
Tensile Tests with r- and n-Value
Determination
Thin sheets are frequently required
to have good ductility and high
strength. r- and n-values are often
also determined via tensile tests in
order to characterize forming
properties; the n-value describes the
work hardening increase in stress
during plastic deformation up to uni-
form elongation, while the r-value
describes the vertical anisotropy. The
n-value is determined from the
tensile stress data and strain values;
for the r-value the transverse strain
on the tensile specimen is
measured. Tensile specimens are
taken from the strip or sheet at set
angles to the rolling direction.
One of the major factors affecting
the r-value is the rolling direction.
The sheet thickness is retained as
specimen thickness, while the paral-
lel length is produced by milling or
punching followed by finishing; for
foils, strips are cut. Zwick offers
various machines and devices for
specimen production from different
sheet thicknesses; requirements for
standard-compliant milled specimen
edges are well catered-for via
collaboration with our specialist
partners.
Zwick supplies a wide range of
standard testing systems for
determining material properties from
tensile tests, starting with table-top
testing machines with 2.5 kN
capacity. Our range of axial and
transverse strain extensometers
simplifies finding the right combination
for the customers requirements and
testing conditions, for inherently
stable sheet a laserXtens laser
speckle extensometer combined
with a video-optical transverse strain
extensometer. This combination is
integrated in a single housing,
forming a unified system, and offers
high robustness, excellent measuring
accuracy and simple handling. The
operator benefits from easier speci-
men changing as there are no
longer any contact elements near
the specimen.
Fig. 1: Tensile test on thin sheet with videoXtens (here with transverse strain measurement option)
14
Ductility Tests
Good ductility tests are in great de-
mand for thin sheet. Typical forming
procedures such as deep drawing
and stretch forming are charac-
terized or investigated in standardized
test methods, for which Zwick sup-
plies Type BUP testing machines,
with drawing forces up to 1000 kN.
An important but complex test is the
determination of the forming limit
curve, from which designers can
derive limit strains which should not
be exceeded during forming pro-
cesses. The optical measurement
technology required for recording
strains during the drawing process is
produced in collaboration with
Zwicks 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
15
Draw-bead Test on Steel Sheets
This test is designed to determine
the coefficients of friction between
steel sheet and cup deep drawing
tool. The ideal lubricant for the deep
drawing process can then be
established, enabling cracks and
creases to be avoided and optimizing
the forming process. The draw-bead
unit can easily be installed in a
standard testing machine. For the
test a sheet metal strip with typical
dimensions 300 mm x 30 mm x 2 mm
is gripped axially in the upper speci-
men grips and the draw-bead tool
closed; the sheet metal strip is then
pulled through the draw-bead tool.
This procedure can be repeated
automatically, the number of repeats
being varied as required. Digital con-
trol of the draw-bead tool clamping
force guarantees reliable, reproduc-
ible measured values, while the tool
die can quickly be changed to cover
different testing specifications.
High-speed Test
Material behavior at high strain rates
is critical for applications in the
automobile industry. Road traffic
accidents involve high material
deformation speeds, which must be
taken into account in automobile
design. The necessary material
properties are determined by Zwick
using high-speed testing machines
from the HTM series. These servo-
hydraulic testing machines achieve
20 m/s on specimens at loads up to
100 kN.
Fig. 1: Z050 materials testing machine with draw-bead tool
Fig. 2: Metal specimen in high-speed
testing machine
Additional Tests for Thin Sheet
Flexure and compression tests
Hardness tests
Shear tests/weld seam tests
Automated testing
16
3.4 Bars and Rods
Bars and rods are long products with
cross-sections up to 240 x 320 mm
2
with a wide variety of uses in rolling
and forging: for use in wire rod and
sections or for automotive forgings
such as connecting rods and steel
rails; generator and turbine shafts in
energy technology; as end products
in bridge building and shipbuilding or
in equipment manufacturing and
storage tank construction. The
demands on their mechanical
characteristics are as varied as their
applications: from high tensile for
structural materials to ductile for
subsequent forming processes.
Tensile Test
Specimens are taken from the
product and prepared for the tensile
test in accordance with product
standards. Sections of products can
be used directly as specimens for
testing if the cross-section of the
product permits; the required loads
can exceed 2500 kN, customized
Zwick systems up to 5000 kN are
operating successfully. This places
particular demands on specimen
grips and clamping, and Zwick
develops specimen grips backed by
new technologies to ensure that
specimens do not fail early due to
the effects of clamping.
Wide range of specimen grips up
to 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 of
microstructures, Rockwell tests and
high-load Brinell test HBW10/3000.
Because the hardness test is easy,
quick and reliable it is frequently
performed and correlated with other
characteristics. With long products
the hardenability of the material is
often determined by establishing the
hardness distribution along a rod
following a tempering and quenching
test (Jominy test). Zwicks product
range contains testing machines for
all required hardness testing
methods and includes automated
Jominy testers.
Hardness testing machines for all
standardized hardness testing
methods
All test load levels which are rele-
vant in practice
Instrumented indentation test up
to 2500 N
Automated and portable hardness
testing instruments
Fig. 1: laserXtens extensometer with videoXtens option for transverse strain
Fig. 2: Jominy test on single specimen
17
1
2
3
5
4
3
4
5
1
2
3
5
4
3
4
5
1
Pair of leaf springs
Cylindrical specimen
Flange
Cross-beam
Pin
Fatigue Test
The areas in which products are
used in transport and energy
technology place particular demands
on the safety of the products and of
components made from them. Ma-
terial properties for fatigue strength
and fatigue limit as determined in
fatigue tests often have a safety-
relevant significance in the choice of
material and design of parts. Speci-
mens are tested under cyclic load
conditions and under through-zero
loading. Zwick can supply as stan-
dard fatigue testing machines up to
600 kN, depending on drive method.
The largest servo-hydraulic testing
machine currently in use handles
loads up to 5000 kN.
Robust servo-hydraulic testing
systems, proven over many years
service
Robust units with electromagnetic
resonance drive
Specimen clamping for all relevant
tests
Controller developed and built/
programmed at Zwick
Fig. 2: Torsion testing device for Vibrophore
Fig. 3: Operating principle of torsion testing
device
Fig. 1: Fatigue test on round specimens
Fatigue Under Torsional
Oscillation
The behavior of round products
under torsion is of interest. For static
testing Zwick supplies drives which
when used in combination with
materials testing machines can apply
torque to the specimen and deter-
mine the corresponding material
properties. It is also possible to
superimpose several load axes and
test the material according to its
use. For fatigue testing under high
torque alternating load, frequencies
up to over 200 Hz can be achieved
in a Vibrophore (HFP) equipped with
special test fixtures. Using reso-
nance conditions means that the
test is both quick and, due to low
power consumption, cost-effective.
Customized device construction
Quick test
High energy efficiency
Very low maintenance requirement
Additional Tests for Rods and
Bars:
Tensile tests at elevated
temperature
Creep tests
Flexure and compression tests
Rotating bar bending fatigue tests
Charpy impact tests
Fracture mechanics tests
1
2
3
4
5
18
3.5 Sections and
Reinforcing Steel
Sections of various materials are
rolled or drawn out of semi-finished
products such as billets or bars; in
many cases they are also welded
from bar material. They are used in a
vast number of applications, re-
quiring a wide variety of mechanical
tests. Together with the reinforcing
steel and ribbed reinforcement bars
so vital to civil engineering they form
a group of important structural
materials which in the case of
concrete-reinforcing steel are
subject to regulatory control.
Tensile Test
Because concrete has high com-
pressive strength but lower tensile
strength, it is reinforced by steel
embedded in it. Reinforcing steels
are mainly produced in diameters
from approx. 5 mm to approx.
60 mm. The smaller diameters are
then further processed into mats or
lattices before having concrete
poured over them on site. Testing
these ribbed steels poses a par-
ticular challenge because apart from
cutting to length, no further me-
chanical specimen preparation takes
place.
The on-specimen strain measure-
ment required for precise determina-
tion of the yield point is predomi-
nantly performed using the Macro
extensometer, which records the
strain up to break reliably with no
detrimental effects to itself.
The Macro extensometer has the
following features:
High robustness for measurements
up specimen failure
Swivelling knife-edge on
sensor-arm tip
Automatic attachment and
removal of sensor arms to/from
specimen
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 are
used to test ductility. The specimen
must not lose strength and no
cracks must be detected on visual
inspection. Various die radii and
anvils are specified, depending on
the standard, the bending angle as a
rule being 90 or 180. For this test
Zwick has hydraulic testing machines
and flexure test kits according to the
standards. If required two test areas
can be installed on electro-mechani-
cal testing machines and used for
flexure and tensile tests, eliminating
the need to change machine set-up
or configuration.
Plug-in system for easy adaptation
of flexure test kit
Flexure test kits are standard-
compliant
Use of two test areas in one
testing machine
Fig 1: Tensile test on rebar and macro
extensometer
Fig 2: Flexure test kit for rebars
19
Shear Test
The weld points of reinforcing mats
and lattices are tested for shearing.
This involves removing specimens
from welded mats and lattices and
placing them in special close-fitting
specimen grips. Specimen grips
used for this type of test must be
accurately matched to the diameter
and position of the ribbed wires in
order not to influence the shearing
loads. Zwick has many decades of
experience in this area and has
developed a comprehensive range of
accessories.
Automation of Reinforcement
Steel Testing
Reinforcing steel is produced in large
amounts and must be continually
tested for production control. Zwick
has developed automated systems
in which specimens, cut to length
from rod material or separated from
mats and lattices, are loaded
manually into magazines, after which
they are tested completely auto-
matically. Artificial ageing at 100 C
can also be integrated into this type
of testing system. Cross-sections
are 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 accuracy
and specimens can be optionally
sorted according to test result for
later visual inspection.
Customized total solutions
Integration of all relevant tests
High availability
Useful options for forwarding fault
reports
20
Cyclic Test
Earthquake protection requirements
for high-rise structures mean that
reinforcing steels for certain countries
must be subjected to specific tests.
Standard-compliant cyclic tensile-
compression tests (carried out on
ribbed steel rods cut to length)
depart significantly from the elastic
range of the specimen. Grip-to-grip
separation, stroke and frequency are
specified by the standard according
to the specimen diameter. After the
test the deformed specimen is
examined visually for cracks. The
power and short-term energy
needed for these tests is consider-
able. Zwick has developed a servo-
hydraulic testing machine with
hydraulic accumulator for this test,
enabling loads of over 1200 kN to be
applied with strokes of more than
20 mm at over 1 Hz.
Earthquake tests to standard
Hydraulic, parallel-closing
specimen grips for compression
and tensile loading
Fatigue Test
Reinforcing steels are required by
standard to have a defined fatigue
strength, which must be verified.
These fatigue tests are most quickly
and economically performed using
resonance pulsators. Zwicks
Vibrophores (HFP) offer an optimum
solution for this application up to
600 kN. Specimens can have a
diameter up to 36 mm; from 14 mm
they must be grouted a grouting
device is available.
Fig 1: High capacity machine for eartquake tests on rebars
Fig 2: Rebar specimen grips
21
3.6 Wire and Cable
All metals can be formed into wire,
which is a very common metal
product form. Wires are used in all
areas of the manufacturing industry:
in construction engineering, in
electrical technology and energy
technology, in aircraft and automobi-
le manufacture and in medical
technology. Wire braided into cables
is used in load-bearing applications in
cableways, lifts and cranes, in
bridge-building, anchorings and
fastenings and in many other areas.
The wide range of applications
places extremely varied mechanical
demands, with the result that testing
material properties is often highly
safety-relevant.
Tensile Test on Wire
Tensile tests on wire represent a
challenge for specimen grip design.
Wires can be very thin and at the
same time very strong; as they
cannot be machined for testing,
cut-off lengths are used and require
suitable gripping arrangements
simply clamping wires between jaws
can cause failure at an unwanted
location. Zwick can supply specimen
grips featuring various gripping tech-
nologies, providing safe, reliable
testing. For strain measurement the
optical extensometer videoXtens can
be used with thin wires, with thicker
wires optical or contact extenso-
meters can be employed.
Wide range of specimen grips for
single wires
The right extensometer for every
application
Fig. 1: Tensile test on fine wire with macro
extensometer
Fig. 2: Clamping device for tension wire
Tensile Test on Braided
Tension Wire
With braided wires several wires are
wound together; under tensile
loading they try to unwind. Zwicks
special clamping technology avoids
premature failure at an unwanted
location. Failure of these braided
wires generally involves individual
fraying wires with high whiplash, and
with a strong probability of damage
to contact extensometers; our
advice is to use optical extenso-
meters.
Optical extensometers:
Long measurement travel
(up to 900 mm)
High resolution of 5 m over whole
measurement travel
22
Tensile Test on Wire Ropes
High strain levels have to be taken
into account during tensile tests on
wire ropes, as do high loads, both
resulting in torn individual wires
whipping back with high energy on
failure. Safety precautions must be
taken to eliminate risks from the
test.
Rotating Bar Bending Fatigue
Test
In many applications, wires are
subjected to various cyclic stresses.
Fatigue strength can be determined
quickly and easily in rotating bar
bending fatigue tests, in which the
rapidly rotating (up to 6000 rpm)
specimen is additionally loaded with
a force perpendicular to the axis of
rotation. This flexure plus the rotation
provides a tensile-compression
loading of the specimen surface.
Specimen preparation is especially
important here, an undamaged
surface being essential. Fig. 1: Horizontal testing machine for wire ropes
Fig. 2: Rotating bend fatigue test system (UBM)
Additional Test Applications for
Wire and Cable:
Torsion tests
Hardness tests
Fatigue tests
23
3.7 Pipes
Pipes transport granulated materials,
liquids and gases; these can be ag-
gressive or neutral.
Pipes are used in widely differing
surroundings, including nuclear po-
wer stations, in and above the
ground for transporting oil and natu-
ral gas, in engines for fuel delivery
and exhaust gases and in the
chemical industry for creating raw
materials. This causes them to be
produced in a wide range of
materials and alloys, using various
production processes, in an
apparently endless variety of forms.
Fig. 2: High capacity machine with double actuator hydraulic specimen grips
Tensile Test
Ways of testing tensile specimens
taken from or consisting of pipes
vary according to the product form.
Small, thin pipes are crushed at the
ends for a sufficient length and then
pulled, while cores are used in larger
diameter pipes to prevent pre-
damage through crushing. With
larger pipes standardized specimens
are produced from material removed
from the wall of the pipe. It is
possible that specimens (taken
longitudinally) may display the curve
of the pipe radius; for reliable, pre-
damage-free testing this radius
should be compensated for with
suitably shaped counterpieces.
Zwick supplies tensile testing
machines from 500 N to 2500 kN,
with appropriate specimen grips.
Fig. 3: Tensile test on pipe wall specimen
Fig. 1: Pipe wall specimen
24
Fig. 1: Compression test
Fig. 2: DWT high-energy drop-weight tester
Compression Tests
Crush tests are carried out on pipes
to test their strength and ductility.
These characteristics can be of
considerable significance in situations
where the safety of pipework must
not be affected by earthquakes,
especially when pipes are laid
directly in the ground. The test areas
of the Zwick materials testing
machine can be set up in
accordance with pipe diameters to
make handling of specimens both
simple and time-saving.
Drop-weight Test
For large oil and gas mains,
specimens from the pipe wall are
subjected to a drop-weight test to
API 5L. Specimens with the height
of the original wall thickness and
widths of several centimeters are
subjected to abrupt loading via a
vertically falling weight with a tup.
The energy (weight and release
height) is set so that the specimen
breaks, allowing the fracture surface
to be assessed visually. Zwick
supplies drop-weight testers up to
100,000 J for this type of test.
Additional Test Applications for
Pipes:
Tensile tests at elevated
temperature
Creep tests
Hardness tests
Weld seam tests
Fatigue tests
Charpy impact tests
25
3.8 Castings and Forgings
Castings and forgings are predomi-
nantly used in the automobile
industry and for aircraft manufacture,
as well as power-station construc-
tion. 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. Forged com-
ponents are used to meet severe
demands on strength, or extremes
of pressure and impact loading, as
with crankshafts and connecting
rods in engines, or generator and
turbine shafts in power stations.
Fatigue Test
In practice, where castings and
forgings are concerned, everything
depends on reliable estimation of
fatigue strength. This requires
specimens and, importantly, entire
components such as connecting
rods to be tested intensively under
cyclic loadings. Operating conditions
are reproduced, in resonance testing
machines for example, and com-
ponents stressed with cyclic loads
up to 600 kN at frequencies up to
300 Hz. Zwicks range of highly
efficient, cost-effective resonance
testing machines is now backed by
a greatly expanded servo-hydraulic
testing machine range.
Fig. 1: Tensile test on round specimen
Fig. 2: Fatigue test on connecting rod in oil
bath
Tensile Test
Cast and forged components are
produced so as to require the
minimum of further processing to
make them fit for their intended
purpose. For tensile tests 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
Fig. 3: Brinell indentation test with ringlight
option
round specimens Zwick provides
special specimen grips which are
easy to handle and allow the use of
automatic extensometers; complete
components are catered for by a
comprehensive accessory and
option package.
Hardness Test
The hardness value is an important
characteristic during monitoring of
the manufacturing process for cast
and forged components. The high-
load Brinell method is often used on
components, the large indentations
enabling a stable average value for
the metallographic constituents to
be obtained. The hardness of metal-
lographic constituents is determined
on specimens via Vickers micro-
hardness testing. Zwicks operator-
friendly Brinell hardness testing
machines with automatic indentation
measurement up to load stage 3000
(29,000 N) are complemented by a
comprehensive micro Vickers
instrument range, including fully
automatic systems.
Further Testing Applications for
Cast and Forged Components:
Tensile tests under temperature
Torsion tests
Rotating bar bending fatigue tests
Charpy impact tests.
26
3.9 Fasteners
First and foremost amongst
fasteners are nuts and bolts in all
their many variations; screws, rivets
and hooks and eyes are also used
to join parts which must not separa-
te under load. Fastener technology
in general, particularly welding and
associated technologies, is
considered here.
Tensile Test
Bolts and screws are selected very
carefully as components for industrial
applications and integrated precisely
into the design. Accurate
determination (via tensile tests) of the
elastic tensile modulus and the limits
of elastic loading is essential, as from
this the limit forces for a secure,
reliable screwed fastening are
established. The huge number of
applications requires a vast range of
screws and bolts of many different
types. Zwicks comprehensive
selection of specimen grips, with the
option of customized solutions,
simplifies testing in this area.
Fig. 1: Shear test on riveted joint
Fig. 2: Screw specimen grips for screws
and round specimens
Shear Test
In addition to single-axis tensile
loading, shear loads also occur in
this application and can quickly
cause a joint to part. Shear tests on
joined parts or specimens are
therefore essential, particularly
where riveted joints are involved.
Accurate load application is essential
to prevent other forces arising in
addition to the shear force and
distorting results. Zwick works with
the customer to develop a
specification for the correct gripping
of the specimen or components and
then produces the required
arrangement. These testing devices
can be simple or very complex, but
always fulfill their requirements.
27
Fatigue Test on Screws/Bolts
In addition to static loading, fasteners
are generally subjected to frequent
cyclic loadings, including vibrations.
Fatigue tests on screws and bolts
(and other items) are most quickly
and efficiently performed in a
Vibrophore, which can apply cyclic
loads up to 600 kN in a frequency
range up to approx. 300 Hz, using
grips tailor-made for screws/bolts
and other fasteners. The magnetic
drive which generates controlled
resonance in the system (and in the
specimen) requires minimal power,
resulting in highly cost-effective
testing.
Fatigue Test on H-shaped
Specimens
In H-shaped specimens the individual
joints are subjected to common
cyclic loading in tension and com-
pression and the fasteners to a shear
effect. H-specimen grips designed
for this test initially distribute the
forces over the entire structure. The
bending-up and resultant loosening
of the structure can be measured
with an extensometer. With the
strain values the testing machine
in this case also a Vibrophore can
provide control of loads or strain,
depending on how the test is
conducted.
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 Applications
on Fasteners
Creep tests
Flexure and compression tests
Torsion tests
Hardness tests
Drop-weight tests
28
4 Quasi-Static Materials
Testing: Products and
Services
4.1 Materials Testing
Machines
Applications
Materials testing machines are used
to determine the strength and
deformation behavior of specimens
and components, mostly under
tensile, compression and flexure
loading. Shear and torsion loads are
also used. These testing machines
feature long travel, wide test-speed
ranges and interchangeable sensors
and tools, allowing testing of speci-
mens and components with widely
differing forms and dimensions,
made from various materials and
materials 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 and
expandability. This allows us to
provide the most suitable machine
for every budget.
The zwicki-Line consists of high-
quality, compact machines. These
portable, easy-to-use single-
column load-frames have been
specially designed for mechanical
testing with low test loads of 0.5 to
5 kN.
The ProLine was developed to
satisfy the demand for cost-
effective testing machines for
function- testing components and
standard tests on materials. The
Pure Portfolio accessory range
for the ProLine ensures an attrac-
tively priced system and short
delivery times. Test loads are from
5 kN to 100 kN.
The Allround-Line provides the
solution to challenging testing
situations and fulfils the most
exacting requirements. It can be
equipped or upgraded via a
comprehensive accessory range
and used with special sensors and
multi-channel measuring
technology.
Load Frames
Our standard production load frames
are rated for loads up to 2000 kN.
We design and manufacture special
versions for specific applications, e.g.
for higher rated loads or horizontally
aligned load frames for testing in the
component installation position.
zwicki-Line Single-Column
Model
This load frame is based on a highly
bend-resistant aluminum extrusion,
which was developed especially for
the zwicki-Line. The workspace is
freely accessible from three
directions, making the zwicki-Line
also suitable for small component
testing and for use as a hardness
tester. This modular systems low
weight and compact base make it
easily portable and it will fit on any
laboratory table.
Fig 2: ProLine Z050TN with CE conforming protective screen
Fig 1: The zwicki line is available in three
different heights
29
Fig 2: Allround-Line floor-standing machine Z600 Fig 1: Allround-Line floor-standing machine
Z100
ProLine Single and Double-
Column Table-Top Machines
ProLine load frames incorporate two
round steel columns, providing
precise crosshead guidance, while
the integrated spindle and guide
protection guarantee reliable opera-
tion in industrial applications or when
testing splintering materials.
Allround-Line Table-Top and
Floor-Standing Testing
Machines
The table-top testing machines are
equipped with two columns made of
patented extruded aluminum. They
are light and highly bend-resistant
and combine the functions of spindle
guide and spindle protection. T-slots
on the outer sides allow simple
mounting of accessories such as
fixtures or safety guards, unrestricted
by the moving crosshead.
All table-top testing machines can
be fitted with stands to bring the
workspace to the optimum height
for the application or operator. This
allows, for example, comfortable
seated operation with plenty of leg-
room, making the system well suited
to wheelchair users also.
Hard-chrome plated guide columns
and a precision ball screw with play-
free spindle nuts guarantee a high
level of precision for the floor-standing
machines. Various crosshead con-
figurations are available, providing
either an upper or lower test area
or both. All load frames with electro-
mechanical drives can optionally be
equipped with a second test area.
Benefits include rapid change to a
different type of test without having
to reconfigure the entire machine.
30
Drives for Quasi-Static
Test Situations
Electromechanical Drives
All electromechanical drives incorpo-
rate play-free, low-wear ball screws
and digitally controlled drives and are
used with load frames rated for test
loads up to 2000 kN. Combined with
the digital measurement and control
system, they offer the following
advantages:
extremely wide, infinitely variable
speed-range
very low speed-settings possible
(from about 0.5 m/min)
highly precise, exactly reproducible
positioning and speeds.
The ProLine and zwickiLine testing
machines are fitted with DC motors.
All other testing machines have
especially low-inertia brushless
three-phase AC motors.
Hydraulic Drives
This drive is located centrally to the
fixed crosshead, making the test
area below easily accessible. A servo
or proportional valve regulates the oil
flow between the hydraulic unit and
differential cylinder. The oil pad in the
upper pressure chamber eliminates
the familiar problem of plunger pistons
jumping when a specimen breaks.
For high test loads in particular, the
hydraulic drive is an extremely cost-
effective solution.
Hybrid Drives
These patented drives combine the
advantages of the electromechanical
drive (high precision) with those of
the hydraulic drive (high forces). As a
result, even long-stroke cylinders
designed for very high loads can be
moved and positioned very precisely.
This approach allows two parallel
mounted trough-rod cylinders
coupled to the moving crosshead to
be traversed with precise synchro-
nism and regardless of their respec-
tive loadings. They follow, accurately
and virtually without hesitation, the
position parameters set by an
electromechanical pilot drive. Special
features of this drive:
long travel range (no adjustment of
fixed crosshead necessary
relatively low load-frame height
ProLine Load Frames and Drives
Model Z005 Z010 Z020 Z030 Z050
1)
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 [m] 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 3
1)
This testing machine is available in two electronics variations.
zwicki-Line Load Frames and Drives
Model 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 [m] 0.2453 0.2265 0.0996 0.0399
Max. power consumption [kVA] 0.44 0.44 0.44 0.44
31
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 1000/2000
3)
1000 600 750/1500
3)
900
Crosshead travel resolution [m] 0.0410 0.0272 0.0136/0.0543
3)
0.0271 0.0163 0.0207 0.0123
Max. power consumption
[kVA] 2 1.9 2.1/2,6
3)
2.3 2.3 4/6
3)
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] 1825/1760
1)
1715/1655
1)
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] 1000/2000
3)
900/600 250 250 200 400
Crosshead travel resolution [m] 0.0270 0.0123/0.0082 0.0035 0.0035 0.002 0.0041
Max. power consumption [kVA] 4/5
3)
5.5/6 7/13
2)
7/13
2)
20/26
2)
20/25
2)
1)
Second dimension applies to version with widened test area
3)
Depending on drive selected
2)
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 [m] 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)
32
Fig 4: SP testing machine
SP Testing Machine
This materials testing machine is
designed for testing steel specimens
-flat, round or sections. It can per-
form tensile tests, together with
compression, flexure and folding
tests, and has an extra-stiff load
frame with a hydraulic central drive
on the upper crosshead, which can
be fixed or movable as required.
Hydraulically operated wedge grips
are provided as standard and test
load measurement is via electronic
load cells. For strain measurement
the Macro sensor-arm extensometer
and the Clip-on extensometer are
available. Despite its size, this
machine requires no special
foundation, but simply stands on
rubber mats placed directly on the
concrete floor.
SP-testing Machines with Hydraulic Drive System for Nominal Loads from 400 to 1500 kN
Series SP400.xx SP600.xx SP1000.xx SP1200.xx SP1500.xx
Max. load [kN] 400 600 1000 1200 1500
Working area:
Height [mm]
1)
100-600 100-600 120-720 120-720 120-720
Height [mm]
2)
0-800 0-800 0-900 0-1000 0-1000
Width [mm] 670 670 700 850 850
Max. travel [mm] 500 500 600 600 600
Travel resolution [m] 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 18
1)
with fixed crosshead
2)
with adjustable crosshead
Fig 1: High capacity Z1200E Fig 2: High capacity Z2000H Fig 3: High capacity Z2000H
33
4.3 Sheet Metal Testing
Machines
Applications
Testing ductility of sheets to common
current standards (DIN EN ISO 20482,
DIN EN 1669)
Testing the influences of surface
treatments and lubricants during
typical forming techniques such as
cupping tests and earing tests.
Testing the effect of tool and
procedure parameters on the
forming process.
Special Features:
Quick, easy test equipment
change (e.g. punches, blank-
holders etc.) numerous modular
upgrading options available
Low piston-cylinder friction, provi-
ding accurate measurement re-
cording and excellent reproducibility
Hydraulic cup extractor via
integrated piston, with piston rod
acting through drawing punch
(BUP 200 upwards)
Swivelling electronic display unit
adjustable to convenient viewing
position all operating elements
ergonomically arranged
Adjustable automatic blank-holder
load-removal during the test allows
cup-drawing without earing
crushing (BUP 200 upwards)
Automatic setting of pre-selected
sheet clamping force after blanking
procedure
Automatic piston withdrawal and
switch-off after end of test via
crack recognition or on reaching
maximum ram stroke (s-limit)
Alteration of deep drawing speed
during test possible (BUP 400
upwards)
Hydraulic opening and closing of
tool 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 and
control electronics for forming-limit curve (FLC)
34
Fig. 2: Zwick/ZHU2.5/Z2.5 universal
hardness testing machine with hardness
measurement head
Fig. 1: Zwick/ZHV30/Z2.5 Vickers hardness
testing machine with motorized compound-
table
4.4 Hardness Testing
Machines and Instruments
Zwick/ZHV20/Z2.5 Vickers
Hardness Testing Machine
The ZHV/ zwicki-Line Vickers
hardness testing machine is
produced by integrating a Zwick
hardness testing device used for
optical methods with a testing
machine from the zwicki-Line range.
The integrated load cell permits
electro-mechanically applied test
loads between 2 and 200 N (ZHV20/
Z2.5) or between 3 and 300 N
(ZHV30/Z2.5). A high-resolution CCD
camera is mounted on a microscope
angled at 90. Indentor carrier(s) and
lenses are integrated into the turret
so that rotating it brings them into
the correct position to make or
measure the indentation
respectively. The turret is provided
with four carriers in total, allowing
various lenses to be used with one
indentor.
ZHU/zwicki-Line Universal
Hardness Testing Machine
The ZHU/Z2.5 universal hardness
testing machines are based on the
zwicki-Line and can be used for all
classical testing methods, including
Rockwell, Vickers, Knoop, Brinell
and ball indentation hardness. They
are also suitable for the innovative
instrumented indentation test used
to determine hardness plus additio-
nal metallic materials parameters
(referred to as Martens hardness,
EN ISO 14577).
The ZHU/Z2.5 features a patented
hardness measuring head (resolution
0.02 m) with integrated digital
depth and force measuring system,
mounted in a zwicki-Line materials
testing machine with modified drive.
Add to this state-of-the-art
testControl measurement and control
electronics and Zwicks intelligent
testing software and the result is a
well-balanced, high-precision
measuring system.
The ZHU/zwicki-Line is available with
two different test areas: 350 mm or
850 mm. To enable high-precision
measurements in the various
application areas, two hardness
measuring heads with exchangeable
indentors and sensor foot are
available: 2 200 N or 5 2.5 kN.
This innovative testing system has
the additional benefit of testXpert

in-
telligent software, which has proved
highly effective in standard situations
such as quality assurance and also
offers an excellent range of options
in demanding areas such as
research and development.
The ZHU/zwicki-Line range is
complemented by a comprehensive,
standardized range of accessories,
including a selection of indentors,
hardness comparison platens,
clamping systems and compound
tables with manual or fully automatic
control.
Sample features:
Multiple curve for direct comparison
of tests in a series
Configuration of user-specific test
sequences: special test sequences
can also easily be defined and
executed
Suitable for production-line testing
35
Fig. 2: Turret capable of holding four indentors and two lenses Zwick/ZHU250 topLine with
testXpert

II connection
Fig. 1: Universal hardness testing machine
Fig. 3: Dark field illumination with ringlight
option
Zwick/ZHU topLine Universal
Hardness Testing Machine (up
to 30,000 N test load)
Todays state-of-the-art universal
testing machines use innovative
electromechanical technology for
high-precision testing in a wide
range of applications, particularly for
quality assurance, production-line
testing and in the laboratory.
Zwicks three ZHU topLine hardness
testing machines ZHU250top (1 -
250 kgf / 9.8 - 2452.5 N), ZHU750top
(3 - 750 kgf / 29.4 - 7357.5 N) and
ZHU3000top (20 - 3000 kgf / 196.2 -
29,430 N) are based on innovative
optical zoom technology, eliminating
the need for frequent lens changes.
The closed loop/load cell load appli-
cation technology provides solutions
for both optical and depth measure-
ment testing in accordance with
recognized testing methods.
Ringlight Option
A further option available is a ringlight
using LED technology. This uses
dark field illumination to produce a
special contrast image which allows
more precise, automatic indentation
measurement, particularly with softer
materials (e.g. < 200 HB), unaffect-
ed by loss of clarity due to edge
bulging.
Revolver Option
One very special feature is the Re-
volver motorized turret optionally
available with the ZHU250 top and
ZHU750 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 a
handwheel) and the result is a top-
of-the-range hardness tester with a
comprehensive range of accessories
available to suit any application.
Intelligent Testing with
testXpert

II (Option)
An integrated RS232 interface allows
transfer of test data to Zwicks
testXpert

II testing software for

evaluation, ready for straightforward
documentation or connection to
quality assurance systems.
36
Fig. 2: Zwick/ZHV30 manual low-load
Vickers hardness tester
Fig. 1: Zwick/ZHV1 micro Vickers hardness test with motorized compound-table and testXpert

Zwick/ZHV1 and ZHV2 Micro

Vickers Hardness Testers
Zwicks micro Vickers hardness
testers are available in two versions
to suit different load ranges: ZHV1
with weights from 10 to 1000 gf
and ZHV2 with weights from 25 to
2000 gf. They can be used for testing
in compliance with the following
standards:
Vickers (HV) to DIN EN ISO6507,
ASTM E 92 and
Knoop (HK) to DIN EN ISO 454,
ASTM E 384.
The same operating concepts are
available for both ranges:
ZHV-m (manual) measuring is
performed manually by the operator,
using a microscope. The automatic
turret allows one-button control
when changing between indentor
and lenses.
ZHV-PC the ZHV1-m and ZHV2-
m can be retrofitted with a CCD
camera for optical evaluation using a
PC system.
ZHV-s (semi-automatic)/ZHV-a (fully
automatic) both feature fully auto-
matic operation to the operators
specifications. The semi-automatic
version differs in having manual
indentation focusing against motor-
ized auto-focusing. Motorized load-
change, automatic indentation
measuring, automatically controlled
turret via testXpert

for changing
between indentor and lens positions
plus control of motorized compound
table and fully automatic test
sequences.
Zwick/ZHV30 Low-Load
Vickers Hardness Tester
The Zwick/ZHV30 manual Vickers
hardness tester covers Vickers (HV)
applications DIN EN ISO 6507 and
ASTM E 92. With a load range of 0.2
to 30 kgf the ZHV30 can also
optionally be equipped for Knoop
(HK): DIN EN ISO 4545, ASTM E
384 and Brinell (HB): DIN EN ISO
6506, ASTM E 10. As with the
Zwick micro Vickers hardness tester,
measurement with the Zwick/ZHV30
is performed manually by the
operator, using a microscope. The
automatic turret allows one-button
operation when changing between
indentor and lenses, while operator
influence during hold time is
eliminated by the fully automatic test
sequence to a specified time frame.
A CCD camera cam retrofitted to
the ZHV30 to enable optical evalu-
ation via a PC system. Optical
measurement of the indentation is
then performed either manually or
automatically with testXpert

connection.
37
Fig. 2: Zwick MIC 10 portable hardness tester
Fig. 1: Zwick/ZHR 8150SK for series tests
with small batch sizes
Fig. 3: Zwick Webster hardness testing pliers
Fig. 4: Zwick PZ3 Brinell testing clamp for
tests up to 3000 kgf
Zwick/ZHR Rockwell Hardness
Testing Instruments
The various instruments in this
product 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 holder
for hardness testing in hard-to-
access locations. Straightforward
operating 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 methods
are used in a variety of ways and are
attracting increasing interest for use
on large or non-transportable com-
ponents and plant for which sta-
tionary, laboratory-based testers are
unsuitable. Zwick has a compre-
hensive range of portable hardness
testing equipment for a wide range
of applications.
Zwick MIC10 Hardness Tester
(UCI method)
The Zwick MIC 10 allows quick, handy,
on-site hardness testing in conformity
with the UCI (Ultrasonic Contact
Impedance, standardized to ASTM A
1038) method. In what is known as
the comparative method, the inden-
tation made by the diamond in the
surface of the material is measured
electronically and the hardness value
is shown immediately in the display.
Zwick DynaPocket Digital
Rebound Hardness Tester
The Zwick DynaPocket is an
extremely handy integrated digital
hardness testing instrument which
uses 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 as
forgings or castings even at
locations which would be difficult for
other testers to reach.
Zwick Webster Hardness
Testing Pliers
Portable, easy-to-use testing pliers
with built-in indentor and spring.
Squeezing the grips together
presses the indentor (via the spring)
into the specimen (material thick-
ness 0.6 - 8 mm) and the
indentation depth is shown on the
scale. The value is read off and
converted to Rockwell hardness
using the chart supplied. These
testing pliers are used for aluminium,
aluminium alloys, brass, copper
alloys and steel in the range
Rockwell E 20 to E 110 (max.).
Zwick PZ3 Brinell Testing
Clamp
This unique portable hardness tester
is suitable for standardized static
Brinell ball indentation tests up to
3000 kgf (29,420 N). Hardness tests
can be performed on materials and
workpieces unsuitable for testing in
the laboratory. Examples of these
include stored steel stocks, finished
structures, machines and larger
metal components.
38
4.5 Measurement and
Control Electronics
The measurement and control
electronic is an essential element of
any testing machine. Its design and
scope determine which drive system
it regulates, which measurement
system it is connected to, and which
functions can be controlled with it.
Zwick testing machines use
testControl electronics. Developed
by Zwick in-house, testControl
features state-of-the-art technology
and the highest possible quality
standards, providing maximum
performance and long-term invest-
ment security.
Special features include:
Synchronized test data recording
of all measuring channels with high
resolution and measurement
frequency
500 Hz real-time processing of
test data for monitoring and event-
oriented control of the test se-
quence (e.g. speed change upon
reaching offset yield or proof stress
limit) and safety limits
Adaptive control for exactly repro-
ducible test speeds and positions
Modular design enables testControl
to accommodate customers indi-
vidual requirements if these
change over time, testControl can
be adapted to suit (e.g. additional
load or strain channels or external
input / output channels)
Direct, synchronous correction in
testControl for testing system
elasticity, providing high positioning
accuracy, including under load.
Fig. 3: Terminal box for multiple signals
In the base model, testControl and
the testing machine are operated via
a PC and testXpert

software,
making the system easy to expand
and configure to suit the most varied
applications and at the same time
extremely flexible and convenient in
operation.
As an alternative to PC operation, an
optional stand-alone variation offers
simple, direct operation via a color
display, a key pad and a few intuitive
function keys. A printer can be
connected directly to output test
results.
This system can also be connected
to a PC, thus providing access to
the benefits of testXpert

software.
Housed in a compact casing
mounted directly on the load frame,
the electronics ensure high overall
availability and reliability of the testing
system.
Fig. 1: testControl electronics Fig. 2: Optional I/O module with terminal
box for synchronous input and output of
external signals
39
4.6 testXpert

II Intelligent
and Reliable, the New
Software Generation for
Materials Testing
With testXpert

, Zwick Roell has set

the standard for intelligent materials
testing software. Unlike other
software, Zwick has standardized
testXpert

for all of its applications,

no matter whether static or dynamic
tests so you spend less time
learning to handle software and
more time conducting tests. With
testXpert

II, you benefit from over

80 years of testing experience and
from over 15,000 successful
installations worldwide.
Some Significant Benefits of
testXpert

II
Ingeniously Simple
testXpert

II is organized so that you

can operate it intuitively. Expressive
symbols and a clear menu structure
enable users quickly to become
oriented and reduce the familiariza-
tion period dramatically. The menu
bar is set up according to the needs
of the user, making working with
testXpert

II ingeniously simple.
Intelligent
Wizards help you to set up or
change test procedures and test
reports. Should you have any
questions, our extensive context-
sensitive online help feature will
quickly deliver the answer.
Modular Design
testXpert

II gives you a software

system tailored to your needs.
testXpert

IIs modular design makes

this possible you only buy what
you need. Upgrading your existing
system with additional test programs
or options is of course no
problem.
Compatible with your Hardware
Zwick testXpert

II is compatible with
all commercially available PCs and
laptops without the need for an addi-
tional interface card! This means it is
easy to switch system computers or
even to develop test methods or
perform analyses in the office at your
convenience. You always have
access to your test data.
Online Language Swapping
Needless to say, you can have
testXpert

II in your language of
choice. testXpert

II speaks more
than one language all you need to
do is click the mouse in order to
change the language online. Regard-
less of the language used for testing,
a test report can be automatically
printed and e-mailed in a different
language. Flexible testXpert

II
language swapping offers internatio-
nal teams language-neutral opera-
tion of their testing machine and
greatly simplifies communication.
40
Industry-oriented Terminology
and Data Export Capability
testXpert

II not only uses your lan-

guage but it also adopts your
technical terminology. For example,
symbols or variables that are specific
to your industry (e.g. metals, plastics,
rubber) are implemented throughout
the software. This provides more re-
levant, meaningful information for
your testing application. Todays
quality assurance standards neces-
sitate that the test results may be
exported to a companys central
laboratory database. So we have
created testXpert

II to commu-
nicate reliably with your IT system by
providing flexible interfaces. All test
results can directly be processed,
exported and archived. MS Office
integration is achieved by means of
Object Linking Editing (OLE).
Strain Control
testXpert

II already incorporates the

latest ISO 6892-1 (2009) revision,
which contains the first normative
inclusion of strain control in this inter-
national standard. The test speed
ranges have narrow tolerances with
the aim of increasing reproducibility
in material property results, especially
proof stress and yield point. This also
has the effect of optimizing test
times, which have a direct bearing
on robotic testing systems with high
specimen throughput.
Select Test Standard
testXpert

II already contains the

correct test program for every
standardized test. Simply select the
required test program all para-
meters are pre-configured in
accordance with standards and can
also be adapted as required. For
non-standardized tests, testXpert

II
provides arange of varied, powerful
testing programs, allowing the test
sequence to be set up completely
as desired.
Testing
The individual data are displayed on
the monitor online as part of the
test procedure, so you can follow
the test procedure live. If desired you
can also incorporate an exactly
synchronized video recording.
The results are calculated during the
test so that the test procedure can
be process-controlled, e.g. by speed
change after determining the Young-
modulus or the yield point. Only in
this manner can the test be per-
formed quickly and in accordance
with the standard.
Fig. 1: Selection of pre-defined test results (tensile test)
Evaluation of Test Results
In testXpert

II you can create many

different screen layouts according to
your needs, for example with additio-
nal graphs, various presentations of
the testing curves, tables and additi-
onal statistics. With one click you
can switch between the various lay-
outs, thus changing the presentation
of your test results
Validation of Testing Software
Reference data sets used for testing
software algorithms can be read into
the data import/export function. On
a European level, reference data
sets of this type for tensile tests have
been generated in a specified data
format in the TENSTAND project and
the associated results have also
been internationally agreed.
testXpert

II testing software and

parameters for calculating results
can be checked quickly and reliably
at any time using this data.
41
r- and n-Value Determination
The r- and n-values are important
characteristics for the forming prop-
erties of sheet metal. When sheets
are being rolled out these values are
used to control the process and
ensure consistent sheet quality.
Zwick testXpert

II supports r and n-
value determination to ISO 10113
and ISO 10275 in metal tensile tests
and includes the revision of the two
standards concluded in 2007. The
simultaneous use of axial and
transverse strain extensometers is
essential for r-value determination
(perpendicular anisotropy) on stan-
dardized flat tensile specimens and
satisfies the conditions of the
standard. The n-value (hardening
exponent) is determined from the
stress-strain curve. If all require-
ments are fulfilled, these two results
can be selected in the results menu
and the standard-compliant results
will appear in the display; they will
also be added to the results list for
the test report.
testXpert

II LIMS
Only testXpert

II offers this feature:

an integrated Laboratory Information
Management System (LIMS). A
powerful database is available to
administer your test results in order
to create and archive long-term
statistics and reports. All data ac-
quired by testXpert

II are available
on any testing system in your
company.
Fig. 2: Long-term display of tensile strength over several days
Fig. 1: Display of determination of r- and n-values
42
Fig 1: Load cell Xforce; design: multiple strain-gage
4.7 Load Cells
Load cells are available for accurate
measurements from 0.02 N.
Together with testControl digital
measurement electronics they offer
the following advantages:
Measurement accuracy: Class 1
(1 % of measured value) from 0.2
to 100 % of nominal force and
Class 0.5 (0.5 % of measured
value) from 1 to 100 % of nominal
force
Insensitivity to parasitic influences
(torque etc.)
High flexural strength limit and
torsional strength limit against
break
Zero point and characteristic value
temperature compensation over
the entire measurement range
Very high effective measured value
resolution and measurement
frequency in combination with
testControl
General overload protection
through testXpert

II; mechanical
protection also available for low
capacity load cells
Automatic identification and
acquisition of all setting and
calibration parameters via the
sensor connecting plug; load-cell
change does not require changing
of set-up data or calibration
Automatic zero point and
sensitivity adjustment
Load cells for testing in two test
areas are available for capacities
above 10 kN (variant with
mounting studs on both sides).
Configurations and
Recommendations for Use
Depending on the testing situation,
other aspects of load cells in addition
to measuring accuracy are of impor-
tance; when optional temperature
conditioning devices are in use (or
during use in factory shops with wide
temperature gradients), zero point
(TkO) and characteristic value (TkC)
temperature compensation are
required. With tensile or compression
tests, lateral forces and moments
occur which must only have a slight
influence on the measurement signal
from the sensor. Zwick supplies two
types of load cells to the following
measurement principles:
Torsion ring load cell:
The body of this rotationally
symmetrical load cell is a torsion
ring with ring-shaped strain-
measuring spirals
Direction of tension
Direction of tension
Design: multiple strain-gage
beams
Measurement is performed by
beams in spoke formation.
Characteristics:
Insensitive to parasitic influences
and overloads.
43
4.8 Specimen Grips
Specimen Grips for Tensile,
Creep and Cyclic Tests
Metals testing is a large field. Its
many applications are covered by
Zwicks extensive range of specimen
grips varying in design, test load
range and testing temperature. The
specific area of application of
specimen grips depends on their
operating principle and maximum
permitted test load; where tests are
performed in temperature or climatic
chambers the temperature range in
which the grips can be used is also
an important consideration.
Load Transfer Between
Specimen and Specimen Grips
The operating principle defines the
type of load transfer between speci-
men and specimen grips and most
grips derive their names from this.
With the majority of specimens, the
test load can only be transmitted
indirectly, i.e. via friction. This means
that the frictional force between the
ends of the specimen and the jaws
of the specimen grips must always
be greater than the test load. The
clamping forces necessary for this,
which act perpendicularly to the test
load, are generated externally (e.g.
by pneumatic pressure) or derived
mechanically from the test load (self-
clamping specimen grips). Jaw
breaks in the clamping area, partic-
ularly with specimens sensitive to
clamping forces (wires and foil strips),
are avoided by a reduction in the
test load before the clamping point.
This is done through sling friction,
achieved by leading the specimen
ends around curved friction surfaces
(e.g. circle segments or rollers)
before clamping them.
Gripping Force
Specimen grips with externally
generated gripping force apply the
set level of force throughout the test.
With thick or soft specimens in
particular, however, specimen mate-
rial can flow out of the clamping area
under the effects of the test load
(grip slippage) reducing the specimen
thickness. With hydraulic and pneu-
matic specimen grips the gripping
force nevertheless remains constant,
as the pressure generator supplies
more pressurized oil or compressed
air. The gripping force of screw grips
decreases to some extent, depending
on the stiffness and resilience of the
grips. Due to the high gripping force
of these specimen grips, specimen
material is forced out of the clamping
area when the grips are closed. The
specimen is subjected to compres-
sive loading and can be pre-damaged
in this way. Similar behavior can
also occur with self-clamping speci-
men grips, as the jaws move to-
wards the center of the specimen
on closing. This effect can be
avoided by appropriate control of the
testing machine drive on closing the
grips (zero force control). With self-
clamping specimen grips the initially
low gripping force increases in ac-
cordance with the test load currently
applied and the operating principle.
Gripping Surface
Frictional force depends on both the
magnitude of the gripping force and
the coefficients of friction of the
contact surfaces. For this reason
interchangeable jaws or jaw inserts
with various types of gripping
surfaces (differing shape, surface
structure, material etc.) are provided
for many specimen grips.
Clamping Travel and Opening
Width
Specimen grips with external grip-
ping force generation have long
clamping travel and thus also a large
opening width, leaving a larger free
area 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 on
the test load for different types of specimen
grips
Clamping force
Tensile force
Hydr. and pneum. grips
Screw grips
Wedge-screw grips
Wedge grips
Pincer grips
44
Overview of Specimen Grips
Selection criteria for specimen grips
Characteristics/features
Size (max. test load)
Smallest version [kN] 10 0.02 0.02 2.5 0.02 0.5 0.5 25 10 0.5
Largest version [kN] 2000 100 0.05 600 50 250 30 250 600 10
Temperature range
Lower limit [C] -70 -70 -15 -70 -70 -40 +20 -70 -70 -40
Upper 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 grips
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45
4.9 Extensometers
In most tensile tests the extension
against the test load has to be
measured; in special cases the
change in width must also be
measured. In flexure tests, the
measured quantity is the deflection.
A variety of extensometer types are
required to cope with differing speci-
men shapes and dimensions, mate-
rial properties (strength, rigidity,
extensibility etc.) material character-
istics to be determined, measuring
accuracies etc.
Requirements for
Extensometers
The requirements for an extenso-
meter are determined primarily by
the physical characteristics of the
material to be tested. Other critical
factors include the shape and di-
mensions of the specimen together
with the relevant test standards and
results to be obtained.
Ambient conditions (temperature,
light, vibration) and costs must also
be taken into consideration, as
should the operating characteristics
of extensometers. Whatever the
application, Zwicks wide range of
extensometers has the right instru-
ment for the job.
The following chart contains an
overview of the criteria affecting the
choice of extensometer.
Crosshead Travel Encoder
A digital crosshead travel encoder is
standard equipment on all Zwick
Standard or Allround materials testing
machines. Its measuring signal is
primarily used to provide an actual
value for the drive system position
and speed control; however, it can
also be used for indirect extension
measurement .
Analogue Clip-on
Extensometers
(clip-on, manual)
The resolution of these extensome-
ters, which can be attached man-
ually or automatically (option) to the
specimen, is extremely high, but
their test travel is relatively short.
They are therefore predominantly
used for high precision determination
of tensile modulus (ISO 527-1) on
rigid and reinforced plastics and to
determine Poissons Ratio (with
simultaneous measurement of ex-
Fig 1: Selection process of extensometers
Extensometer Portfolio
Measuring Priciple,
Properties
Functionality
(auto / manual)
Environmental
conditions
Purchase,
Running Costs,
Ease of Use
Specific Test Application
Comparsion and selection process
criteria (must have / should have)
Material
(component)
Test Method,
Standard
Environmental
Influences
Budget
Material
Properties
Specimen, Test
Sequence, Test Result
Temperature, Light,
Noise
Purchasing,
Running Costs
Extenosmeter
Properties
Extensometers
Requirements
tension and change in width). For
determination of Youngs modulus
from a tensile test, measurement on
both sides with an extensometer is
strongly recommended.
Fig 2: Clip-on extensometer
46
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 manually
applied extensometers feature high
resolution and relatively long mea-
surement travel, allowing them for
example to be used for precise
determination of initial slope and
proof stress to ISO 6892, EN 10002
and ASTM E 8. Where specimens
have low extension, strains can be
determined beyond proof stress, at
maximum stress and at break.
Biaxial Digital Clip-on
Extensometer
(clip-on, manual)
Manually applied axial/transverse
strain extensometer with large mea-
surement ranges and high resolution
for r and n-value determination to
standard; fulfils the requirements of
Class 0.5 to EN ISO 9513.
Long-travel Extensometer
Used for measuring higher strains on
thin, highly elastic wires. Drag forces
for these applications are kept par-
ticularly low, at less than or equal to
0.2 N. The system has a high level
of insensitivity to specimens wrapping
around the sensor arms after break.
High resolution and measurement
accuracy
Low drag force
Robust construction
Optical Extensometer
Digital extensometer featuring non-
contact measurement for tensile
tests on wires and stranded wires;
can also be used for applications in
temperature chambers, in which
case measurement takes place via
a heated window.
No drag force
Reliable operation via signal
pattern recognition
Easy to handle
Fig 2: Biaxial digital Clip-on extensometer
47
Fig 3: multiXtens
Fig 1: Macro extensometer
Fig 2: Transverse strain extensometer
Fig 4: optiXtens
Macro Extensometer
The Macro is the workhorse among
extensometers used in metals tes-
ting. It is suitable for tensile, com-
pression and flexure tests and also
for cyclic tests on all metals. It is
primarily used on standard flat tensile
specimens, but also on thin strips
and 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 well
as for cyclic tests on materials with
low 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 detaching
sensor 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 Laser
Speckle method. It is used for tensile
and compression tests on materials
with low to high extensions, both at
room temperature and in
conjunction with temperature
chambers.
Advantages:
Optical system not requiring
measurement marks
Easy to operate
No drag-force influence
Reliable, accurate deformation
measurement until specimen
break
Particularly suitable for
measurement in temperature and
climatic chambers
Transverse Strain Extensometer
For r-value determination the Macro
can be expanded with options for
transverse strain measurement. The
options contain 1, 2 or 4 measure-
ment lines.
Resolutions down to 0.01 m.
48
Fig 1: videoXtens
Fig 2: laserXtens
Extensometers: Overview
Long-stroke Optical Makro multiXtens optiXtens videoXtens
1)
laserXtens
extensometer
System digital digital digital digital
2)
laser- image laser-
speckle evaluation speckle
Measuring range, mm 1000 L
0
1000 L
0
min. 75 700 L
0
500 L
0
50...200 40
max. 160 700 L
0
(viewfield)
Resolution, m 5 5 0.12...0.6 0.02...0.04 0.1 1 0.15
Accuracy cl. 1 >_ 1mm cl. 1 >_ 3 mm class 0.5/1
4)
class 0.5/1
4)
class 0.5 class 1 class 1
(ISO 9513) 1% or 1% or
0.01 mm
3)
0.03 mm
3)
Gauge lengths, mm 10...1000 10...900 10... >_ 5 >_ 10 >_ 5 1.5-220
100/205/300
Drag force, N <_ 0.20

<_ 0.050 <_ 0.015

Autom. sensor arm

optional

Autom. L
0
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-resolution
extensometer for tensile and
compression tests on all product
forms of metals, especially on
standard specimens. Resolution and
measurement range can be adapted
to current test conditions via easily
changed lenses. Simultaneous
transverse strain measurement of
the specimen is optionally available.
Advantages:
Adaptable to various materials and
test conditions
Parallel measurement of
transverse strain (optional)
Reliable, accurate strain
measurement until specimen
break
Automatic gauge length
recognition
Suitable for measurements in
temperature chambers through a
heated glass panel
laserXtens
laserXtens provides contact-free
measuring of deformations on a wide
range of materials, its measuring
principle rendering gauge marks
unnecessary. laserXtens is used for
tensile and compression tests on
metals 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 integrated
videoXtens
Suitable for testing small
specimens at high resolution
49
Application
During assembly of a materials tes-
ting machine it is normal practice to
incorporate the high-temperature
unit directly into the machine. This
type of arrangement allows tensile
tests to be carried out at both am-
bient and raised temperatures.
During testing at ambient tempera-
ture, components such as the
high-temperature furnace, high-
temperature extensometer and pull-
rod are simply swung out of the test
area. Using a centrally divided folding
furnace allows the pull-rod in use
to remain in the machine. After the
rod has cooled down it can be re-
moved via a quick-change system.
4.10 High-Temperature
Testing Accessories
The high-temperature system
consists of three main components:
The swivel-mounted high-
temperature furnace
The high-temperature
extensometer, which can also
simply be swiveled out of the test
area. It is moved up to the
specimen directly via a slit in the
furnace:
The pull-rod, comprising
connecting pieces for the quick-
change system and the pull-rod
itself, via which the tensile load is
transmitted into the furnace, and
the specimen grips at the end of
the pull-rod.
In practice the most common speci-
mens are threaded-end specimens,
as described in DIN 50125 . Flat
specimens are produced from thin
sheets and are held in positive-fitting
flat-specimen grips. Standardized
specimen grips in various materials
are available for these specimens in
the temperature range up to 1200 C.
Standardized units are also available
for compression and flexure tests up
to 1600 C. The volumes present in
the furnace, the temperature
tolerances and hold-times specified
in the standard; these plus heating
and cooling times mean that the
duration of tests is more or less fixed
- and decidedly time-consuming. To
shorten specimen throughput time,
systems with several furnaces are
available 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-temperature
specimen grips for flat specimens
50
4.11 Creep Test
There is currently a great deal of
interest in saving energy and
reducing environmentally harmful
emissions. This is particularly the
case with turbine technology as
used in power stations (e.g. gas and
steam turbine rotors) and aircraft
turbine blades. One approach to
increasing efficiency is to raise
operating pressure and temperature,
for which the development of new,
high-temperature-resistant materials
is vital. The creep test is one of the
most important experiments for
describing the high-temperature
behavior of materials (standardized in
others ASTM E 139 and ISO 204
and elsewhere), as proven material
properties obtained over an ex-
tended period are essential for the
design and operation of high-
temperature components. Creep
testing involves two different time-
frames.
For short-term creep tests up to
1000 h load-time, lead-screw-driven
creep testing machines are often
used, in single or twin-screw
designs. This type of drive allows
relaxation tests (constant strain and
temperature) to be performed in ad-
dition to creep tests. For long-term
tests > 2500 h, dead weight machines
are often used with load applica-
tion usually by lever. It is essential for
the mechanical and thermal loading
of the specimen to be both constant
and precise. Values determined are
load time until break, creep strain
limits and high-temperature strain,
e.g. creep strain. A comprehensive
range of solutions is available for
standard-compliant performance of
these demanding tasks:
Mechanical Loading Unit
comprising load frame, drive and
pull-rod:
Load frame with (one or two) lead-
screw drive(s) and precision guide
for precise, axial loading
Load frame with lever loading and
calibrated dead weights
Load frame with lever loading and
load-cell-controlled drive
Pull rod with optimum alignment
characteristics to ASTM E 1012
Electronics
High-resolution force and travel
measurement for optimum control
characteristics at very slow test
speeds.
High-temperature Unit
High-temperature furnace with six
thermal elements for optimum
temperature control
Vertical furnace-positioning accor-
ding to specimen strain
Integrated universal self-optimizing
HT controller guarantees obser-
vance of strict limit values (e.g.
ASTM E 139: +/- 2 K) for spatial
and temporal specimen tempera-
ture stability, with zero over-swing.
Empirically determined set values
for each heat zone according to
specimen and furnace geometry
are not necessary; all that is need-
ed is to specify the temperature
set 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 temperature

rising continuously to set values and active/
automatic heat zone control
Fig. 3: Open furnace including thermal
elements
51
4.12 Robotic Testing
Systems
Application
Robotic testing systems are used for
efficient performance of large test
series on the same type of specimen
and are available in the following
application-specific versions:
roboTest A
roboTest C
roboTest F
roboTest L
roboTest R
roboTest P
roboTest I
Common Features
Modular system allows flexible
combination of individual
components
Standardized control of robotic
testing system via autoEdition2
automation software with control
via Profibus
CE-compliant stand-alone system
Data exchange with any Zwick
materials testing machine via serial
interface
Uses standard industrial
computers.
Advantages for Users
Minimal operator requirement (just
load the specimen magazine!)
High reproducibility of test
conditions and test results
Secure documentation and
statistical long-term monitoring
Manually controlled tests also
possible
Modular system allows easy
adaptation and expansion to meet
specific requirements.
Configurations and Operation
roboTest A
roboTest A is attached to the load
frame and is designed for tensile
tests on metals up to approx. 500 g
weight per specimen. The magazine
can hold 20 specimens; all robot
actuators are pneumatically
operated.
roboTest C
The roboTest C testing system is
suitable for tensile tests on dimen-
sionally stable flat specimens weigh-
ing 0.5 5 kg and can be attached
to 300 600 kN testing machines.
The magazine usually contains
around 20 to 40 specimens, which
are held in portable carriers.
roboTest F
The roboTest F robotic testing
system is used for tensile tests
(including non-rigid specimens). It
consists of a movable base, with ho-
rizontal upper and lower chains
forming an oval carousel equipped
with spring clamps or magnets for
gripping specimens in a vertical
alignment. Various gripping
arrangements for differing specimens
can also be used in combination.
Depending on the type of clamping
and specimen, broken specimens
can be returned to the magazine
area.
Bild 2: roboTest L Bild 1: roboTest F
52
roboTest L
roboTest L can be used for tensile,
compression and flexure tests. It
consists of a movable base plus
electronics units, a linear feed axis,
pincer grips and optional movable
magazine table, the whole unit being
controlled by a programmable logic
controller (PLC). Cross-section can
be measured automatically at up to
3 places.
roboTest R
roboTest R is used for tensile tests
and comprises a 5 or 6-axis
industrial robot with a pneumatic
gripper arm. The complete system
features modular design, allowing
hardness and roughness measuring
equipment etc. to be integrated,
together with a bar-code reader and
cross-section measuring device.
roboTest P
The roboTest P robotic testing
system is used for tensile tests and
for hardness, roughness and layer-
thickness measurements. Its larger
dimensions and design allow several
testing machines to be used in one
system. The system consists of 3
axes and a swiveling gripper unit and
is controlled via a programmable
logic controller. A safety housing for
the whole system is required and
can be included in the quotation on
request.
roboTest I
roboTest I is used for impact tests
on Charpy specimens with a pendu-
lum impact tester, at both plus and
minus temperatures, to EN 10 045
or ASTM E23. The specimen dimen-
sions (length x width x thickness) are
usually 55 x 10 x 5 - 10 mm and the
standard temperature range is from
-180 to +300 C. Specimen cooling
is by means of nitrogen, while
heating is electric.
Data Processing Technology
Specimen data and test results from
all systems can be printed out and
saved or transferred via an interface,
e.g. a local PC network, to a sub-
ordinate computer system for report
generation and production moni-
toring. Data transfer to MS Office
programs, e.g. via ODBC, is also
possible.
Fig. 1: roboTest R
53
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-dimensionally
stable 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. 50
Specimen 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

Options
Thickness measurement manual manual manual
Specimen rest removal
Barcode identification
Roughness
Hardness
Cout thickness
Automated hardness Test
Application
For this test a hardness testing
instrument for Rockwell methods
HR15T, HR30T, HR45T, HRF, HRB
and HRG is connected to a roboTest
L, roboTest P or roboTest R robotic
testing system.
Overview
Fig. 1: Automated hardness test with two
hardness testers
Fig. 2: Automated tensile test with integrated hardness test
54
Typical Round Specimens (Fig. 2, Specimen Type b)
Standard Dimensions [mm]
d L
0
D L
c
L
DIN EN 10002 (Anh. C) 4 100/200 L
0
+ 50
DIN 50125, Form A 10 50 12 60 140
12 60 15 72 160
16 80 20 96 205
ASTM E 8 12.5 50 60
8.75 35 45
JIS Z 2201 No 4 14 50 60
Typical Flat Specimens for Tensile Test
Standard Dimensions [mm]
a b L
0
B L
c
L b
DIN EN 10002, Typ1 12.5 50 75 165 0.003
DIN EN 10002, Typ 2 20 80 30 120 250 0.052
DIN 50114 3 20 80 30 120 250
DIN 50125 3 8 30 12 38 115
5 16 50 22 65 175
6 20 60 27 80 210
8 25 80 33 105 260
JIS Z 2201 (13A) 20 80 30 120
JIS Z 2201 (13B) 12.5 50 20 60
JIS Z 2201/ 5) 25 50 30 60
JIS Z 2201/1B) 25 200 30 220
JIS Z 2201/1A) 40 200 220
ASTM 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 kN
Series RZ50 RZ65 RZ100 RZ150
Structural shape C - frame O-frame O-frame O-frame
Cutting force [kN] 500 650 1000 1500
Specimen throughput [1/min] 8 8 6 6
Specimen thickness [mm] 0.2 - 6 0.2 - 6 0.2 - 6 0.2 - 8
Max. power
consumption [kVA] 4 4 8 8
4.13 Specimen Preparation
Specimen Blanking Machines
Blanking for economical production
of tensile specimens from sheet
metal. Work hardening by the
cutting edge amounts to a maxi-
mum of 10 % of specimen thickness
due to the low cutting speed and
the shape of the blanking tool. The
small amount of stock and with it
the work hardening is removed
using the specimen grinder.
Zwick 7120 Specimen Grinder
Grinder for grinding specimen blanks
to shape and size and removing
work-hardened areas. Height of
entire grinder unit (max. power
consumption 0.75 kVA) is adjustable,
enabling accurate grinding of parallel
specimen length.
Fig 1: Specimen blanking machine
Zwick RZ 150
Fig 2: Specimen types
Calculation of blanking force
when selecting specimen
blanking machine
Blanking force P in kN
If P 650 kN, then:
L
s
= total cut length in mm

B
= tensile strength in MPa
= specimen thickness in mm
Fig 3: Specimen grinder Zwick 7120
P =
L
s
x x
B
x 0,64
1000
P =
L
s
x x
B
x 0,8
1000
55
5 Fatigue and Impact
Testing: Products and
Services
Special Features
Precisely aligned load frames
featuring extremely high stiffness
Hydrostatic bearings, making the
actuators virtually frictionless - and
also wear-free
LVDT extensometer with high
resolution and linearity integrated
centrally in the actuator rod
Fig 1: Servo-hydraulic testing machine
Amsler HC 25
Fig 3: Servo-hydraulic testing machine
Amsler HA 100
Fig 2: Servo-hydraulic testing machine
Amsler HB 250
Precision strain-gauge load-cell for
mounting on actuator rod or fixing
to crosshead as required
Wide range of hydraulic power
packs
Comprehensive range of accesso-
ries (specimen grips, extensometers,
temperature chambers etc.)
5.1 Fatigue Testing
Machines
Servo-hydraulic Testing
Machines
Servo-hydraulic testing machines are
universally applicable for materials
and component testing under
pulsating or alternating load, with
periodic or random signals. Quasi-
static and continuous loading are
also easily achieved.
Servo-hydraulic Testing Machines (STM) Standard versions
1)
Model
2)
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 request
2)
Testing actuator mounted on upper crosshead of HC and HB frames, base-mounted on
HA frame
56
Amsler HC-compact
The Amsler HC-compact servo-
hydraulic testing machine consists of
a hydraulic power pack, test frame
and test actuator and is suitable for
materials and component testing
under static and oscillating loads.
Advantages
Space-saving design with inte-
grated hydraulic power pack
Whisper-quiet power pack allowing
installation without additional noise
protection measures in virtually any
laboratory
Testing actuator mounted in top
crosshead permitting easy set-up
for flexure and component testing.
T-slot platform hard-chromed for
tests with corrosive media, e.g.
saline solutions
Seal-free testing actuator with
hydrostatic bearings, guaranteeing
significantly longer maintenance-
free operation than with any other
design.
Amsler HCT and HBT Tensile
and Compression/Torsion
Testing Machines
The servo-hydraulic testing
machines in the Amsler HCT and
HBT series are used to test the
behavior of materials and
components under combined tensile
and compression/torsion loading.
The tests can be performed with
pulsating, cycling and static loading.
Features
Standard load frame from HC and
HB range.
Tensile and compression/torsion
drive mounted in upper/fixed
crosshead and consisting of:
- longitudinal actuator with hydro-
static bearings
- length compensation
- rotary actuator
The length compensation allows
play-free transmission of the
torque to the rod of the longitudinal
actuator. The rotary activator
remains fixed and is not subject to
axial movement.
Combined load cell/moment
sensor
Tests under discrete load can also
be performed, e.g. axial load only.
Fig 1: Servo-hydraulic testing machine
Amsler HC-compact
Fig 2: Tensiel, compression, torsion testing
machine Amsler HBT
Specification
HC-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)
Specification
HCT 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
57
Fig 1: HydroWin 96xx Controller
HydroWin 96xx
Outstanding features of the HydroWin
96xx control and measurement
electronics include:
10 kHz closed-loop control and
data acquisition
19-bit A/D conversion with real-
time linearization
Real-time measurement channels
for derived measurands also (e.g.
totals or differences)
32-bit set-value generation for any
required functions up to 1kHz
Adaptive control for non-linear test
applications (e.g. testing rubber
components or polymers)
Multi-channel control
(up to 9 control channels)
Control of external units
Comprehensive basic and
application software.
Workshop 96 Test Software
for HydroWin 96xx Controller
Workshop 96 is universal testing
software for fatigue and durability
tests on materials and components,
with a large number of application
programs for standard tests such as
fracture toughness determination,
low cycle fatigue, damper testing
and so on. A valuable additional
facility is upgrades for modernizing
older load frames from most
manufacturers.
Function
The HydroWin 96xx digital control
and data acquisition system plus
Workshop 96 software represent a
fully-integrated testing solution in a
user-friendly Windows environment,
providing test engineers with access
to 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 96
and with the HydroWin 9600
controller provides an integrated
testing environment with real-time
graphs, actual value displays
(adjustable for running values), upper
peak, lower peak, peak to peak or
mean values.
testXpert

Dynamic
Zwick also provides a range of
testXpert

software for specific test-

ing applications, including low cycle
fatigue, torsion testing, multi-stage
continuous testing, and elastomer-
metal component testing. Configuration 96
This software from the Workshop 96
Framework enables the HydroWin
96xx control and measurement
electronics to be configured to use
measured-value transducers and
channels as required. Analog, digital
and mathematically-derived trans-
ducers can be configured and
assigned to channels. Connection
and disconnection of transducers is
automatically detected by the
HydroWin 96xx controller and the
software.
58
Vibrophore with Electro-
Magnetic Resonance Drive
Zwick are suppliers of the world-
famous Amsler HFP Vibrophore, the
first version being introduced by
Amsler in 1945. It is valued by test
laboratories in the automotive sector
for its high-level performance and
low 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. fatigue
tests in accordance with DIN 50100
(S/N curve), in tensile, compres-
sive, pulsating and alternating load
ranges
Fatigue strength and durability tests
on components such as springs,
crankshafts, connecting rods,
fasteners, steering knuckles etc.
Fig 2: Amsler HFP 250 Vibrophore Fig 1: Testing of round specimen
Fracture mechanics tests on CT
or COD specimens
Testing under various environ-
mental conditions (temperature,
aggressive media)
Specimen pre-cracking for torsion
and bending tests
Production and quality control of
components exposed to dynamic
loading during their service life
Measurement and Control
Electronics
Control and monitoring of these
testing machines is via VibroWin
control and measurement elec-
tronics, with test definition, display
and result evaluation by Zwicks
proven testXpert

software.
Fig 3: Testing of flat specimen
Vibrophore: Specifications
Model, 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
59
5.2 Impact Testing
Machines
Amsler HTM Servo-hydraulic
High-speed Testing Machine
Application
Servo-hydraulic high-speed testing
machines are predominantly used for
high-speed penetration tests and
high-speed tensile breaking tests.
Speeds are easily selected over a
wide range from very slow to maxi-
mum. Typical applications are aimed
at material characteristics at high
elongation rates, crash simulations
or better understanding of materials
in rapid forming processes. These
include:
Tensile tests on flat and round
specimens
Tensile, peel and shear tests on
joining technologies
Control and Measurement
Electronics
testControl electronics plus testXpert

software provide comprehensive

test-result evaluations, together with
report creation and data manage-
ment.
Fig 2: High-speed testing machine Amsler HTM 5020 Fig 1: testXpert

screenshot of a high-speed
test
Amsler HTM Servo-hydraulic High-speed Testing Machine
Specifications 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
60
Fig 3: Pendulum impact tester PSW 750 Fig 2: Pendulum impact tester RKP 450
Pendulum Impact Testers
Application
Pendulum impact testers are used
to determine impact energy, impact
strength and notched impact
strength of standardized metal
specimens and components. The
design and layout of our pendulum
impact testers conform to all rele-
vant standards, allowing safe,
reliable, Charpy and Izod testing,
plus impact tensile tests to Brugger,
in compliance with international
application standards. To
accommodate differing materials,
specimen cross-sections and test
standards, pendulums with potential
energy up to 750 joules, standard-
compliant specimen supports and
clamping fixtures are available; these
are easy to change, with no need
for time-consuming adjustment.
Features
Stiff, torsion-free frame with low-
friction pendulum mounting (the
energy 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.
Accessories
Partly or fully automatic temperature
conditioning, feed and testing of
Charpy specimens at both positive
and negative temperatures to
EN 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 to
max. -180 C), storage capacity up
to 21 specimens. Heating takes
place electrically, while heat transfer
between specimens and the tem-
perature conditioning unit is conduc-
tive (solid body contact). A standard-
compliant notch form is crucial for
obtaining reliable results from the
impact test; Notch Vision provides
swift, optical measurement of both
notch and Charpy specimen
dimensions.
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 with
semi-automatic specimen feeding and
tempering
Fig 1: Notch Vision
61
Drop Weight Testers
High-energy Drop Weight
Testers for Testing Pipeline
Sections
Application
The American Petrol Institution
requires pipes for use in pipelines to
be subjected to a drop-weight test.
Standardized drop weight testers
specifically designed for this applica-
tion can apply various impact
energies and speeds according to
requirements. Zwick drop weight
testers can be used to test Batelle
specimens 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 adjustment
required
Test area is mechanically and
electrically protected via a safety
circuit test cannot begin until all
safety contacts have been
monitored; additional independent
pneumatically operated safety
locking bar prevents test area
accidents
Touch-screen operation with
electronic display of fall height,
impact energy, drop weight and
impact velocity
Infinitely adjustable fall height
position is automatically
implemented after input of drop
weight and impact energy
Drop weight is divided into individu-
al weights for adjusting impact
energy
Fig 1: High-energy drop weight tester DWT 40 (max drop height 5 m)
62
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] 50x77x305 50x77x305 50x77x305 50x77x305 50x77x305 50x77x305 50x77x305 50x77x305 50x77x305
Fig 1: Pellini drop weight tester P550
Pellini Drop Weight Testers
Application
Drop weight test for investigation of
brittle fracture tendency of steels to
SEP 1325 and ASTM E208 to
W.S.Pellini.
Energy Required
Max. 550 - 1630 J, drop weight
22.5 - 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.
63
6 Modernization Packages
for all Makes of Materials
Testing Machines
Zwick ZMART.PRO
Modernization and Retrofit
Technology
Modernizing a testing system can be
an economical alternative to buying
a new one, especially with testing
machines with high nominal force,
special load frames or complex pe-
ripherals. Many of the existing com-
ponents such as extensometers or
specimen grips can be adapted to
the new technology and continue in
use.
Whoever built it Zwick has the
right solution for every make
Zwick provides modular moderniza-
tion kits which can be adapted
individually to suit a wide range of
requirements.
Modernization Packages for
Materials Testing Machines
with Electro-Mechanical and
Hydraulic Drives
Quasi-static materials testing ma-
chines (with electro-mechanical or
hydraulic drive) can be re-equipped
to state-of-the-art level using the
testControl modernization package.
Modernization involves the following
basic elements:
testControl digital control and
measurement technology
testXpert

testing software
Maintenance-free, precision-
controlled AC drive
Adaptation of existing sensors.
Additional elements for hydraulic
materials testing machines:
Proportional or servo valves
New hydraulic power pack or
adaptation of existing hydraulic
components.
Modernization Packages for
Servo-Hydraulic Testing Systems
Zwicks HydroWin 96 and Control
Cube modernization packages provide
a wide range of options for moderniz-
ing servo-hydraulic testing systems of
many different makes.
The conversion kits comprise the
following components:
HydroWin 96 and Control Cube
digital measurement and control
electronics
testXpert

/ Workshop 96 testing
software
New hydraulic power pack or
adaptation of existing components.
Zwick also provides special moderni-
zation options for vibrophores, high-
speed test rigs, creep test machines
and pendulum impact testers.
New from Old
We only use components from the
current production ranges, providing
your newly modernized machine
with the same level of technology as
a comparable new machine.
testXpert

is standard software, so
both new and modernized machines
are equipped with the same operat-
ing platform.
Following modernization, users enjoy
renewed long-term reliability,
guaranteed spare-part supply and
access to the whole Zwick acces-
sory program.
Detailed information regarding con-
trol and measurement electronics
used can be found on pages 38 and
57.
Fig 1: Servo-hydraulic testing machine
Zwick REL2041 after the modernization
with HydroWin 96XX
Fig 2: Materials testing machine Zwick 1455
after the modernization with testControl
64
7 Zwick Services
Applications Laboratory and
Contract Testing
In the last few years Zwick's appli-
cations laboratory has become to a
competence-center of materals
testing with active scientific
exchange.
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 and
special regulations
Advice on products, testing
methods and test performance
Laboratory for Fatigue and
Impact Testing
Determining S-N curves for fatigue
strength measurement of bonds,
structures, and weld seams
Fatigue test investigations under
multi-axial load
Fatigue strength investigations
under 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 material
behavior (LCF)
Determining fracture mechanical
characteristic values
Performing tests under impact
test force
Application of measuring methods
to obtain the relevant mechanical
values (crack propagation, crack
detection, local strains, tempera-
ture sequence etc.) for specimens
and components
Laboratory for Quasi-Static
Applications
Tensile, compression, flexure and
torsion 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-static
applications
65
Further Services
Worldwide Service
Customer satisfaction is our first
priority at Zwick Roell AG. Local
service organizations in over 50
countries work to ensure optimum
utilization and maximum availability of
your testing system.
Engineer Consultation Service
New testing assignments with chan-
ging requirements, building or
upgrading a testing laboratory - only
with the aid of specialists can you be
sure of getting what you want.
Experienced Zwick engineers advise
at the planning stage of complex
projects and then help you achieve
the reality.
Demonstration
There are many factors to consider
before deciding to acquire a
materials testing system and
accessories. To make that decision
easier, the application technology
laboratory at Zwick's headquarters
offers you the opportunity to
experience various solutions to a
wide range of testing situations.
Test drive
For new, altered or highly complex
applications, Zwick offers you the op-
portunity to carry out a practical test.
The application technology laboratory's
experts and comprehensive range of
equipment are at your disposal.
Application Technology Seminars
Active co-operation with associates
in research and technology enables
the Zwick Academy to organize
seminars on the basic principles of
materials testing, its applications and
the current level of knowledge.
Pre-Delivery Inspection
Before final delivery of a machine,
customers have the opportunity to
carry out a pre- delivery inspection
at our premises, where they can
satisfy themselves regarding scope
of delivery and try out the functions
stipulated in the order. We also
provide an introduction to operating
the system.
Transport
If required, Zwick Service will, as
part of the commissioning process,
provide full transport supervision. We
can also provide business-to-
business transport and deliver the
machine to the desired location at
your premises.
Installation
With several thousand successful
commissionings under our belt, you
can rely on Zwick Service to provide
the best possible installation service
for machine and/or accessories.
Pre-handover function tests in the
customer's presence help make
installation trouble-free.
Hardware Familiarization
Nothing is left to chance at Zwick
Service when a new system is
commissioned. Professional, system-
atically constructed checklists help
you get the most out of our products.
66
Software Familiarization
Specially produced checklists using
concrete examples from everyday
practice help you become familiar
with our software, with results being
saved for later use. Alternatively, we
offer a 2-stage induction course,
consisting of a basic introduction as
part of the commissioning process,
followed by an expanded induction
at a later point in time.
Machine Relocation
Zwick Service will organize the relo-
cation of your testing machine from
start to finish. Our experienced
project management team will take
care of the detailed planning of
disassembly, transport and recom-
missioning. Zwick will see to it that
your testing machine is ready and
waiting at your new premises.
Software Adaptation
With our software engineers' depth
of expert knowledge and many
years of experience, you can rely on
Zwick to deliver programming per-
fectly adapted to your individual
requirements. Working closely with
our customers, we identify their
testing requirements and still in
close collaboration deliver the right
package for the job.
Product Training
Qualified trainers with industry ex-
perience provide product training.
We also offer individual training
tailored to customers' requirements.
This is available in-house or at our
premises.
Hotline
First priority is for your testing ma-
chine to be in perfect working order.
Should faults develop in your machine
or software, in spite of their high
quality, our expert staff are ready to
help you via the Zwick Hotline. Your
call will be returned in the shortest
possible time.
SupportDesk
For further advice or assistance,
such as technical or software sup-
port, the Zwick SupportDesk is in
many cases a better option than an
on-the-spot visit. Our experienced
staff will use their wide-ranging
technical knowledge to provide you
with an answer speedily and
effectively.
Rental
Whether for short-term testing
requirements or just to try them out,
Zwick Service has the specimen
grips you need.
Maintenance
Zwick Service can perform the
necessary scheduled maintenance
of machines and accessories as
detailed in the operating manual and
will also ensure that service intervals
are maintained.
67
Servicing
Zwick Service helps you reduce
downtime significantly through regu-
lar servicing of your testing
machines.
The condition of the machine is re-
corded at the service and necessary
repairs are carried out and wear
parts replaced immediately, where
possible. The service engineer will
also advise on preventive and/or pre-
cautionary measures.
Repairs
If, in spite of careful servicing and
maintenance, a fault develops in a
machine, one of our many service
engineers will be with you in the
shortest possible time, while spare
parts can be delivered within 24
hours.
Calibration
Zwick's calibration service is
accredited by DKD
1)
, UKAS
2)
,
COFRAC
3)
and A2LA
4)
to DIN EN
ISO/IEC 17025 for on-site calibration
of materials testing machines.
The reference measuring equipment
used is regularly recalibrated. De-
pending on the customer's require-
ments, either a works calibration
(Zwick calibration certificate), ISO
calibration (Zwick certificate with
documentation showing measuring
equipment supervision to ISO9001)
or DKD calibration (DKD certificate) is
performed.
If necessary, the testing machines
and associated sensors will be
adjusted during calibration.
1)
DKD: Deutscher Kalibrier-Dienst
2)
UKAS: United Kingdom Accreditation
Service
3)
COFRAC: Comit Franais dAccrditation
4)
A2LA: American Association for
Laboratory Accredition
Software Upgrade/Update
An update gives you access to the
ongoing development of testXpert

software and opens the door to an

expanded range of functions.
Changes to testing standards are
also incorporated into the latest
versions.
Upgrading from an old DOS operat-
ing system to the latest Windows
equivalent provides a secure, reliable
route to the new technology. Up-
grade from testXpert

to testXpert

II
and enjoy access to all the latest
testXpert

developments, with their

many benefits for everyday use.
68
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 (Whler 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 Page
Standard
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 (Whler 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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