We carry out material tests with competence and reliability in our well-equipped material test laboratories. We also have a vehicle equipped as a mobile test lab which allows us to carry out tests directly at our customers’ premises.
We have many years of experience in this field and are able to offer our customers and partners target-oriented solutions in all questions of material testing. This applies to material tests of components and materials in various industries such as machinery and plant engineering, automotive, rail vehicle construction, traffic engineering, civil engineering, chemical industry, metallurgy, energy supply technology, gas and oil industry, as well as other industries.
Our range of services include individual parts, series and on-line testing, assessments, research and development, technical advice as well as welding technology and monitoring.
Our services include:
In the modern industry, material tests are an important and indispensable part of quality assurance. Destructive materials tests serve the monitoring of thermal processing or the determination of chemical and physical material characteristics. We offer the following services in the field of destructive material tests:
Laboratory spectrometer “Spectrolab“
The equipment system analyses the following chemical elements in the metallic sample matrix:
There is a wide range of techniques and methods for non-destructive material tests. Non-destructive test methods are often used as verification during the production process or as intermediate tests during the development and production process. We are happy to help you with the selection of suitable test methods for your application, and with the preparation of test specifications and test instructions. We offer the following services in the field of non-destructive tests.
Amongst others, digital ultrasonic testing instruments Echograph 1085, Epoch III as well as a wide range of standard and special test probes (the measured values and ultrasound screen images can be saved and transmitted to a computer).
The dye penetrant test is a testing method for the detection and verification of irregularities such as cracks, pores, incomplete fusions, overlaps etc. on metallic and non-metallic components which are open towards the surface. The procedure can be used for all components whose surface isn’t extremely porous, and which are not sensitive to the penetrant.
The non-porous, cleaned surface is coated with a coloured or fluorescent contrast medium which is able to penetrate the finest cracks and pores due to the capillary attraction. Subsequently, the component surface is cleaned. The fluorescent penetrant remaining in recesses such as cracks and pores will be visualised by means of UV light. For coloured penetrants, a so-called developer with a high colour contrast to the penetrant is applied, which makes the contrast medium remaining in the recesses visible. The evaluation of the crack pattern is effected visually.
The magnetic particle inspection is a procedure for the detection of surface-open cracks and near-surface defects on components made of magnetisable steel and cast iron.
After the application of a magnetic powder, the components is magnetized by applying electric tension or introducing an external magnetic field. Due to the low magnetic conductibility of air in comparison with the ferromagnetic component, the field lines will escape the component mainly at material separations. This causes the formation of visible magnetic powder lines at cracks and cutting lines. The magnetic power is applied either wet with water or oil as a carrier medium, or dry as a powder, and it can be seen due to the fluorescence or the colouring/colour contrast.
The procedure is particularly suitable for components with a complex and irregular geometry. Customers for surface crack tests are mainly working in automotive engineering as well as pipeline and container construction.
Another focal point of our service range is the inspection of damages regarding material problems of different types.
Tasks and goals of damage inspections
The damage analysis mainly serves the identification of reasons for the failure of a component or material. Moreover, it is used to prevent further damages by retroactions on the constructions, material selection, production processes, test methods and operating conditions as well as by inspection and, if necessary, replacement of vulnerable components of machines, devices, equipment and systems that are in operation.
Information on the damage case
Detailed and reliable information simplify the damage inspection significantly and largely prevent incorrect assessments. This is why we always try to inspect and document the damage on-site. But of course, we also gather information with the necessary diligence for sent-in damaged parts in order to create an exact damage analysis.
Realisation of the inspection
The procedure and scope will be coordinated with the customer. In doing so, the suitable test procedures will be specified. The most important procedures for damage inspections can be divided into the main groups metallography, fractography, mechanical test and chemical analysis.
Evaluation and recording
The procedure, test results and conclusions are summarised in a damage report. The test results are evaluated and possible remedial actions are identified and recommended.
The metallographic inspection of sections is one of the routine tests carried out at every damage inspection due to its versatile applications. Sections are divided in macrosections and microsections.
For the production of macrosections, a material sample is precision-ground and etched with corresponding macro etchants. This is a good way to visualise macrostructures such as number and composition of layers of a weld seam as well as welding defects, hardening zones of surface hardened or case-hardened parts, and cast structures.
For the creation of microsections, a material sample is precision-ground, high gloss polished and then etched with corresponding micro etchants to visualise the structural condition of a material. With a light microscope and suitable magnification, the fine structure of microsections can be evaluated.
In many cases, this allows us to draw a conclusion regarding certain characteristics of a material as well as irregularities or distinctive features. From the visible structure, it is possible to draw conclusions regarding the production method and the state of heat treatment of the reviewed material.
The focus of a damage inspection is the identification of the cause of damage. By means of systematic inspection of fractured surfaces using macro and micro fractography, it is often possible to prove which strains are causing damages. For macro fractography, we use the visual inspection as well as the macroscopic inspection using the stereo microscope.
The micro fractographic evaluation of surfaces is carried out using a scanning electron microscope (SEM). With micro fractography, we can examine, for example:
- whether it is a fatigue failure
- whether a brittle or ductile forced fracture is present
- if the fracture was aided by the influence of hydrogen or corrosion
- if there are microscopic surface damages and how they are structured
When it comes to the evaluation of different surface fractures, the inspection under the SEM is indispensable. Due to the large magnification, it is possible to obtain precise information on the structure of the fractures and changes to the surface.
In combination with an energy dispersive analyser (EDA), it is possible to carry out element analyses, concentration gradients and elemental mapping images at different magnification stages. This enables, for example, the determination of the chemical composition of corrosion products or finest structural constituents, with which conclusions can be drawn regarding factors causing the damages, material irregularities or particularities.
Mechanical tests support the damage analysis in two areas:
They gather the actual material values and compare them with the specified target values.
Tests for the simulation of mechanical overstrain are carried out using corresponding test procedures.
For hardness measurements, we have hardness tester for the procedures according to Vickers, Brinell and Rockwell. Moreover, we can realise tests within a load range from HV 0.01 to HV 1 using a low load hardness tester.
For the determination of mechanical and technological characteristics, we have a computer-assisted traction engine. We are also able to realise Charpy impact tests within a temperature range from -80°C up to + 100°C.</p
A chemical analysis gives information about the composition of the used material and on possible material confusions. Our laboratory spectrometer “Spektrolab” analyses 22 chemical elements in the metallic sample matrix.
In addition to material tests, we offer the following services:
We offer consultation on questions on materials engineering and material tests as well as in the field of welding technology, and prepare assessments in these areas (e.g. assessments on damage inspections that can be used in court).
Application tests and problem analyses: