Creep Seminar Ruchti

Intelligent testing
Creep Testing
with Messphysik
Peter Ruchti
Hereford, September 2012
Agenda
Creep testing with Messphysik
Actual potential
Working principles metals
Working principles plastics / composites
Furnace and temperature
p
controller
Customer projects on metals
Customer projects on plastics
Customer projects on other materials
Creep Testing with Messphysik - Base
September 2012
DI Peter Ruchti (MSc.)
Actual potential
Today there is a high need of energy saving and reduction of emissions.
With higher temperature (T) and pressure (p) the efficiency of HT-systems will be
better and therefore energy and emissions can be saved or reduced.
HT-Power plant
Steam turbine
500 . 650 C
170 bar .
> 700C
> 350 bar
Aerospace
Petrochemical Industry
Gas turbine
960 . 1200 C
50 bar .
> 1200C
> 110 bar
September 2012
Actual potential
Plastic used as a basic material in several industries combines some important
advantages: constant quality, reliability and in distinctive energy efficiency.
Engineering plastics and fiber-reinforced plastics enable new developments in:
Automotive
Aerospace
Battery, body panels,

bumpers, dashboard,
door panels, fuel system,
interior and exterior trims,
lighting systems, seats,
seatbelts, airbags, under
shields
upholstery
Extensive use of plastic

composites in the
Boeing 787 Dreamliner
reduces weight, fuel consumption
and allows new design concepts.
Wind energy
Rotor blade
Housing
September 2012
Actual potential
The consequence: A need of new High Temperature (HT) Materials and relevant material data.
Need of material strength data
Higher pressure
higher mechanical
load
creep, stress rupture strength, creep rupture strength
Stress and creep rupture tests
Higher temperatures
Tensile strength, strain limits, E-Modulus
higher thermical
load
Quasi-static tests
Life time prediction with cyclic loads
Cost reduction
less conservative
part dimensioning
optimized service
intervals
Fatigue tests
September 2012
Actual potential
Messphysik order entry: Academia, Energy and Metal are the
most dominant industries.
Creep order entry by industry
2008-2012
4%
3%
26%
Academia
Automotive
Energy
1%
Metal
Paper
46%
Plastics
20%
Textile
September 2012
Actual potential
Messphysik order entry: The European market makes up over
half of the creep order entry. A quarter of the creep order entry
arises from the Asian market.
Creep order entry by regions
2008-2012
2%
1%
7%
8%
46%
11%
Home market
Rest of Europe
Asia without China
China
USA
Russian Federation
Latin Amerika
26%
September 2012
Agenda
Actual potential
p
controller
September 2012
Working principles - metals

Direct Load
Lever Arm
Spindle
Dead
Weight
Dead
Weight
Spring
Loaded
Single
Spindle
Dual
Spindle
> 10.000 h
> 10.000 h
> 10.000 h
< 10.000 h
< 10.000 h
Control
mode
Force
Force
Force, Stress,
Strain
Force, Stress,
Strain
Force, Stress,
Strain
Load strings
in one frame
~ 100
~ 12
~ 12
Multi
Schematic
Run duration
September 2012
Working principles
Lever arm creep testers schematic diagram 1
l0
l1
F = W(l0/l1)
10
September 2012
Working principles
Lever arm creep testers schematic diagram 2
end switch
0.05
load cell
F
s
Dead weight: force = const.

Spring load: force

orce,, stress, strain = const.
11
September 2012
Working principles
Principle Creep Test: lever arm with dead weight
limit switch
0,05
loading and load control by gravity

automatic adjustment of lever arm at
creep of specimen
control parameter: balance of lever arm
application: creep test with constant load
W
F
100%
According to
weight distribution
2%
F= constant
12
September 2012
Working principles
Principle Creep Test: lever arm with preloaded spring
loading by preloaded spring
load controlling by controlling the
load cell =
control
extensometer =
load cell signal
measurement
channel
application: creep test

with constant load or loading blocks
100%
stepless
0,5%
F/=
F/
= constant
13
F/
F/ = block
September 2012
Working principles
Principle Creep Test: lever arm with preloaded spring
load cell =
measurement
extensometer =
control
loading by preloaded spring

strain control by controlling the
channel
Extensometer signal
application: relaxation test
or other strain controlled tests

14
September 2012
Working principles
Spindle-driven creep testers schematic diagram
Load
cell
Load
cell
Closed loop
control
Closed loop
control
Single-spindle drive
Dual-spindle drive
15
September 2012
Agenda
Actual potential
p
controller
16
September 2012
Working principles plastics and composites
Direct Load
Lever Arm
Spindle
Dead
Weight
Dead
Weight
Single
Spindle
Multistation
> 10.000 h
> 10.000 h
< 10.000 h
< 10.000 h
Control
mode
Force
Force
Force, Stress,
Strain
Force, Stress,
Strain
Load strings
in one frame
~ 100
~ 12
~6
Schematic
Run duration
17
September 2012
Multi-station creep testers schematic diagram

6x
Load
cell
Load
cell
Load
cell
Load
cell
Load
cell
Load
cell
6x
1x environmental chamber
6x closed
loop control
Multi-station creep testers
18
September 2012

The most dominant machine type with creep tests on plastics is the
multi-station creep tester.
1 to 6 test axes per load frame
Central spindle with each test axis and

individual closed-loop-control
One temperature chamber for 1 to 6 test

axes
Alternatively two temperature chambers in

one load frame (each for maximum 3 test
axes)
Non-contacting strain measurment

(recommended by testing standards)
19
September 2012

Strain measurement with Multiplexing shematic diagramm
n-Specimen
in field of view
of 1 camera*
Camera for
non-contacting Extensometer
up to 12
Multiplexing of cameras
Multiplexing Controllers
on 1 Master-PC
up to 256 Multiplex-PCs
Multi-station
Master-PC
* dependant on gage length, elongation and
Load Lift
distance between stations, Standard: 3-4 specimen

20
September 2012

Strain measurement with Multiplexing advantages
Accuracy of each station measurement + 0,01mm
Fixed cameras therefore no uncertainty due to

moving cameras
Continuous measurement from backside of the

testing system
Loading of new specimens does not interrupt

measurement of other stations
Free definition of time schedule for strain

measurement
21
September 2012

Multistation Master PC with testXpert Multistation Software
Test monitoring with tree structure
e.g. automatic measuring of channels,
time, strain and temperature
Detection of break/rupture
Data storage incl. continuation of
interrupted test
Test analysis
Results acc. to ISO 899-1 and ISO
899-2, ASTM D 2990, e.g. strain rate,
creep strength, creep modulus
Statistics
Automated reporting
22
September 2012
Agenda
Actual potential
p
controller
23
September 2012
Furnace and Temperature Controller

High temperature furnace
An important component of the creep system
3-Zone furnace up to 1.200C / 1.400C
Precise temperature distribution by 3-zone-temperature-controller
Internal Diameter: 100 mm, Heated length: 300 mm
Vertical positioning of furnace:

furnace stays in the centre of the specimen
openings for load string, Thermocouples and Extensometers

(optional: side windows for optical strain measurement)
3 Thermocouples for furnace controller;

up to 3 couples for Temperature
control at the specimen
Light, thermal insulation material (free of asbestos)
Casing made of stainless steel
24
September 2012

The intelligent control-algorithm minimizes efforts when
setting the control parameters and ensures standard compliant
specimen temperatures without overshoots.
Automated settings with

the 3-channel
temperature controller
for specimen
temperatures between
80C and 1.200C
1 200C
Timesaving and
optimized use of
specimen because the
complex empirical
determination of controlparameters is no longer
required
Temperature tolerances
according to ISO 204
und ASTM E 139
Screenshots
vorlufig
25
September 2012

The Zwick temperature controller is timesaving and
flexible in use.
3-channel Controller (Eurotherm 2604)
Integrated, technical sophisticated control-algorithm for a

constant temperature deviation along specimen and to
avoid temperature overshoots
Empirical determined control parameters for different

temperatures are no longer required
Not sensitive to different air flow conditions (openings, etc.)
Interface for 6 thermocouples

3 pcs. to control the specimen temperature
3 pcs. to measure the furnace temperature
Digital display of temperature
One RS 232 Interface to PC with 6 virtual channels
Stand Alone- or testXpert-operation possible
Can be used for different 3-zone-furnaces
26
September 2012

The individual PID Parameters are set automatically.
Push/Pull rod
Furnace
12 0 0
1 2 1 5
1 2 0 3
Specimen
Thermocouple
m
1 2 0 0
PID
Slave
Temperature
Slave
1 2 0 0
PID
Master
PID
Temperature
Heating Element Heating Element Heating Element
1 2 0 0
Temperature
PSlave
ID
Temperature
1 2 0 1
1 2 0 1
1 1 8 2
1 1 9 9
Push/Pull rod
Individual PID-setting for each controller

under consideration of
mutual cross talking of the controllers, the load inputs, the specimen and the set
temperature
27
September 2012

The multi-channel control-algorithm controls the
specimen temperature precisely.
PIDTemp_1
PIDTemp_2
PIDMaster
PIDTemp_3
28
September 2012

Even with lower test temperatures the specimen temperatures
stay within the temperature tolerances of +/-2K.
Temperature in
n C
Example: test at 80 C, function of specimen and furnace temperatures
Furnace temp
temperature
perature
Specimen temperture
1,6
Test time in h
29
September 2012

Also with high furnace temperatures, temperature tolerances are
attained quickly without overshoots.
Temperature in
n C
Example: test at 1.000C, function of specimen and furnace temperatures
1000
950
900
850
1,0
1,2
1,4
1,6
1,8
Test time in h
30
September 2012

The flexible control of the furnace temperature enables precise
temperature blocks on the specimen.
Temperature in
n C
Example: test with temperature blocks of 5 C
110
105
100
95
Test time in h
31
September 2012

Optimized heating parameters make short heat-up times possible.
Therefore higher specimen through-puts can be achieved.
Temperature in
n C
Example: When mounting a specimen in a preheated furnace

further warm up times are reduced.
Opening of preheated furnace =

interruption of
controlling
Closing of partly cooled

down furnace
= restart of controlling
Due to the reduction, the

heat-up time comes up to
37 minutes
Time interval of
specimen replacement
Test time in min

32
September 2012
Agenda
Actual potential
p
controller
33
September 2012

Institute of aviation materials, Russia
Type of Test:
High Temperature Tensile Creep Test
Testing Machine:
Kappa 50 SS
Kappa 50 DS
Applied Standard:
ASTM E 139
ISO 204
Specimen Types:
Flat, threaded head (M10/8 / M14/10)
Environment:
Elevated temperature up to +1.200C
Strain:
Creep test with strain measurement on specimen
Customer specific feature: Axial- & Transversal strain measurement
34
September 2012

35
September 2012

36
September 2012

Atomic Research Institute, India
Type of Test:
High Temperature Creep Crack Growth Test
Testing Machine:
Kappa 50 SS
Applied Standard:
ASTM E 1457
Specimen Types:
CT-Specimen
Environment:
E i
t
Ambient
A bi t and
d elevated
l
t d ttemperature
t
up tto +1.200
+1 200 C
Strain:
Measurement of load line deflection with

rod-in-tube extensometer, measurement
of creep crack growth with DCPD method
37
September 2012

38
September 2012

Measurement of creep crack
growth with DCPD-Connection
Measurement of
load line deflection
Output signal
(potential drop)
Power supply
39
September 2012

In a single test both load line displacement and crack size is
measured. Example: CCG test with CT-specimen at 5.985N and 700 C
Standard force
Standard fforce in N
Displacement
e in mm
Load line displacement
Creep time in h
40
September 2012

In a single test both load line displacement and crack size is
measured. Example: CCG test with CT-specimen at 5.985N and 700 C
Force
Crack size in mm
Standard force
o
in N
Crack size
Creep time in h
41
September 2012

Nuclear Research Center, France
Type of Test:
High Temperature Tensile Creep Test
Testing Machine:
Kappa 50 DS
Applied Standard:
Customer specific
Specimen Types:
Material: zirconium
Flat, round and tubular specimen,
(coupling by Swagelock clamping)
Environment:
Ambient and elevated temperature up to +600C
Strain:
Optical measurement of axial strain and

reduction in width
Customer specific feature: Tunnel between Extensometer and HT-furnace 2

optical windows in HT-furnace
Test Results:
Creep Curve
42
September 2012

43
September 2012

44
September 2012

The axial and the transverse strain is measured contactless
under high temperature.
dL/t
Example: Start of creep test at 450C
db/t
0.08
0,08
0.08
0,08
0.02
0,02
0.02
0,02
Change in
width
inin width
mm
m
Change
in
n mm
0.06
0,06
Strain in mm
m
Strain in m
mm
0.06
0,06
0.04
0.04
0.00
0,00
0,00
0.00
00
2
2
44
66
Test time in hours
Test time in h
45
88
10
10
September 2012

Landing Gear Company, Netherlands
Type of Test:
Strain creep test
Testing Machine:
Kappa 50 LA spring
Applied Standard:
ASTM F519
Specimen Types:
Round, threaded head
Test time:
up to 200h
Customer specific feature: 4 specimen in series in the testing axis
46
September 2012

47
September 2012

Test process to determine hydrogen embrittlement acc. to ASTM F519
1. Tensile testing to determine breaking strength
2. Creep testing with 75% of breaking strength
a. All 4 specimen resist the test of 200h > no hydrogen embrittlement of
specimen and specimen surface treating
force
b One specimen breaks during test ->

b.
> test continues with 75% of force until
200h of total test time is reached. Then increase of force in 5%-steps (2h
test time for each step) until the force has reached 90%.
t = 200
2h
90%
2h 85%
2h 80 %
75 %
4 specimen
3 specimen
time
t=x
t = 200-x
t = 206
48
September 2012

Atomic Research Centre, India
Type of Test:
Creep, relaxation,
user-programmable loading cycles
fracture toughness
Testing Machine:
Kappa 100 DS
Applied Standard:
ASTM E 139, ISO 204

ASTM E 399,, ISO 12135
Specimen Types:
metal and ceramics specimens
Environment:
metal up to +1.200C
ceramics up to +1.600C
Loading:
constant stress creep tests
Customer specific feature:
1 furnace up to +1.200C and

1 furnace up to +1.600C
This furnaces are alternately pivoted
49
September 2012

Creep test machine for multiple materials, environments and
applications.
50
September 2012

Tests at ambient temperature
Bending Test
Tensile Test
51
September 2012

Tests at high temperature
Creep Tensile Test
Creep Crack Growth
52
September 2012

The true strain rate can be automatically controlled.
With compression tests the crosshead speed is decreasing.
Deformation in %
Example: Compression test with true strain rate of 0,1% / sec
53
September 2012

Very low traverse speeds are possible.
dL/t
Example: 1 m / hour
100
Strain in in
m m
Strain
80
60
40
20
0
0
2000
Test Test
time
in min
time in min
54
4000
6000
September 2012

Compliance to a corridor of +/- 0,1% at a traverse-speed of 1m/h.
Nominal strain
s
in m
Nominal strain /t
Test time in h
55
September 2012
Agenda
Actual potential
p
controller
56
September 2012

Specialty chemicals group, Germany
Type of Test:
Creep and relaxation tests and

user-programmed stress cycles
Testing Machine:
2x Kappa 50 SS 5 x 10 kN
Applied Standard:
ISO 527-2 Type 1A
Specimen Types:
Tensile specimens of plastic

Tensile
according
1A
T
il specimens
i
di tto ISO 527-2
527 2 Type
T
Tensile specimens with shoulder width 35 mm
Environment:
Ambient temperature up to + 200C
Loading:
Motor via ball screw drive
Strain:
Optical strain measurement
Customer specific feature: 5 load trains together in 1 temperature chamber

Distance of the test axes to each other: 105 mm
Creep Testing with Messphysik
57
Feber 2012

58
Feber 2012

59
Feber 2012

Creep curve easily displayed with testXpert determination of
minimum creep speed and three creep phases
Example: Tensile Creep Test at 60 C and 16 MPa
60
Feber 2012

Front view
Rear view
61
Feber 2012
Agenda
Actual potential
p
controller
62
September 2012

Technical University, Austria: ceramics
Type of Test:
Creep compression tests
Testing Machine:
Kappa 100 SS
Specimen Types:
35mm, h=70mm
Environment:
Elevated temperature up to + 1.600C
Loading:
up to 10.000 h
Strain:
strain measurement from two opposing

positions, max. compression 5-8%
Customer specific feature:
Tests on refractory materials
Creep Testing with Messphysik diverse Materials
63
September 2012

Technical University, Austria: ceramics
64
September 2012

The two-sided measurement of the compression is displayed
in testXpert both separately and averaged.
Example: Test at 1.500 C and konstant force of 7.500 N
65
September 2012

Technical University,
y, Austria: creep tensile tests on refractory
material
erial
watercooling
loadstring
alignment unit
water cooling input
water cooling output
adhesive area
refractory material
heated zone
adhesive area
water cooling input

water cooling output
66
September 2012

Creep Seminar Ruchti

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Intelligent testing

Creep Testing with Messphysik - Base

Creep Testing with Messphysik - Base

Battery, body panels,

Extensive use of plastic

Creep Testing with Messphysik - Base

creep, stress rupture strength, creep rupture strength

Stress and creep rupture tests

Tensile strength, strain limits, E-Modulus

Life time prediction with cyclic loads

Creep Testing with Messphysik - Base

Creep Testing with Messphysik - Base

Creep Testing with Messphysik - Base

Creep Testing with Messphysik - Base

Working principles - metals

Creep Testing with Messphysik - Base

Creep Testing with Messphysik - Base

Dead weight: force = const.

Spring load: force

loading and load control by gravity

Creep Testing with Messphysik - Base

load cell signal

application: creep test

loading by preloaded spring

Creep Testing with Messphysik - Base

Creep Testing with Messphysik - Base

Working principles plastics and composites

Creep Testing with Messphysik - Base

Working principles plastics and composites

Multi-station creep testers schematic diagram

Multi-station creep testers

Creep Testing with Messphysik - Base

Working principles plastics and composites

1 to 6 test axes per load frame

Central spindle with each test axis and

One temperature chamber for 1 to 6 test

Alternatively two temperature chambers in

Non-contacting strain measurment

Creep Testing with Messphysik - Base

Working principles plastics and composites

Creep Testing with Messphysik - Base

* dependant on gage length, elongation and

distance between stations, Standard: 3-4 specimen

Working principles plastics and composites

Accuracy of each station measurement + 0,01mm

Fixed cameras therefore no uncertainty due to

Continuous measurement from backside of the

Loading of new specimens does not interrupt

Free definition of time schedule for strain

Creep Testing with Messphysik - Base

Working principles plastics and composites

Creep Testing with Messphysik - Base

Creep Testing with Messphysik - Base

Furnace and Temperature Controller

3-Zone furnace up to 1.200C / 1.400C

Precise temperature distribution by 3-zone-temperature-controller

Internal Diameter: 100 mm, Heated length: 300 mm

Vertical positioning of furnace:

openings for load string, Thermocouples and Extensometers

3 Thermocouples for furnace controller;

Light, thermal insulation material (free of asbestos)

Casing made of stainless steel

Creep Testing with Messphysik - Base