Highlights testXpo 2017

AllroundLine up to 250 kN – Focus on Testing Applications

AllroundLine is modular, expandable and future-proof, with optimum matching of all mechanical, electrical and software components plus the extensive range of accessories. Modular design allows the testing system to be used for a wide range of tests as and when required.

  • Flexible test arrangements avoid the need for fixture changes, maintaining result repeatability.
  • The new extensometer mounting system, with generous provision of attachment options on the machine frame, avoids disruptive influences from tremors and vibrations in the surrounding area.

Ergonomic operating philosophy
Convenient, operator-friendly working conditions are a key element of materials testing. Zwick materials testing machines can be adjusted for optimum ergonomic configuration; their modular design allows adaptation as and when required. All components are perfectly matched and can be conveniently adapted to suit the testing situation.

  • Working height can be adjusted to suit individual requirements.
  • Test area illumination facilitates accurate insertion of specimens while enhancing operator safety.
  • The new storage and add-on system allows the workplace to be arranged to suit individual requirements, offering secure, efficient storage for accessories - whether calipers, specimen grips or load cells.

Safety combined with technical perfection
We assess the safety risk of the application in question and supply a CE-compliant testing system. Tamper-proof safety devices in accordance with EN ISO 14119 and 14120, together with a monitored work area, form the basis of a unique safety concept. This naturally applies also to applications using temperature chambers. Maximum machine stiffness, high-quality precision guides, a high-resolution, maintenance-free AC drive and state-of-the-art closed-loop control technology guarantee reliable test results.


Temperature chambers by Zwick - reliable test results at temperatures from - 80°C to + 250°C

Exact temperature control for accurate, repeatable test results
The innovative air-feed system used in our temperature chambers ensures extremely uniform temperature distribution. Temperatures are attained quickly and accurately via pre-configured control parameters, while precision control ensures a stable temperature with no overshooting. Operation of all system functions such as temperature chamber fan speed is intuitive and convenient thanks to Zwick's testXpert III testing software. All data can be documented traceably with the test series.

Operator influence minimized, delivering cost and time savings
Specimens are temperature-conditioned in the specimen magazine and are centered quickly and precisely by means of the special insertion aid. Changing specimens through the optional small chamber-door opening minimizes temperature changes and ice formation, enabling reproducible test results. Operator influence is effectively minimized in repeat tests.

Modular and future-proof
"Made by Zwick Roell" - these low-vibration temperature chambers provide optimum operating conditions for all extensometers available from Zwick Roell, guaranteeing reliable test results for both optical and contact-type measurements. The modular concept allows optimum (as well as retrospective) adaptation of the temperature chamber to meet individual requirements. The large chamber volume provides additional test area space for component testing and enables a constant temperature to be maintained in the area around the specimen.

200 kN sheet metal testing machine

Application
Hole expansion test on metal sheets as per ISO 16630 with optical detection of the crack plus subsequent evaluation

Key features

  • BUP 200 sheet metal testing machine with testControl II electronics and testXpert III testing software
  • Covers all established sheet-metal testing standards (e.g. EN ISO 20482, EN 1669).
  • Testing effects of surface treatments, coatings and lubricants
  • Maximum test load 200 kN
  • Maximum punching and clamping force 275 kN
  • Deep drawing speed 1200 mm/min
  • Ram stroke 80 mm
  • Stepless electronic adjustment of clamping force and deep drawing speed via proportional valves

Advantages and benefits

  • Convenient test operating/viewing position from above
  • Triple safety concept for risk-free operation
  • Two-handed operation ensures operator safety during opening and closing of tool head
  • Fast, easy changing of fixtures and tools, including drawing-punch, drawing-die, blank-holder, cutting-punch, cutting-ring and scraper-ring. Numerous modular expansion options.
  • Height-stop, blank holder force and deep drawing speed all steplessly adjustable
  • Low piston-cylinder friction enables accurate measurement recording and excellent reproducibility
  • Test tools/fixtures from earlier machine generations or for different force-ranges can be used in most applications
  • Display and output of measured values in freely configurable reports via testXpert III
  • Accurate, repeatable crack detection (ISO 16630)
  • Deformation of Marciniak specimens to a defined degree
  • Automatic measurement and calculation of test results
  • Time-synchronous recording of test
  • Clean and quiet in operation. Compact dimensions - easy to transport

Small Vibrophore range (25/50 kN)

Zwick has extended its Vibrophore range. The proven 100kN to 1000kN Vibrophores have now been joined by versions with force levels 25 kN and 50 kN.

Application

Fatigue tests on threaded fasteners

Key features

  • Vibrophore 25/50 with 4-column load frame with T-slots
  • Zwick load cell with integrated accelerometer
  • testControl II digital measurement and control electronics with 10kHz control frequency and 24-bit resolution
  • Test device for chains
  • testXpert Research testing software

Advantages and benefits

  • Fully functional static and dynamic testing machine with stiff four-column load frame
  • Easy to install - no ancillary units or systems (e.g. hydraulics, coolant) needed
  • Maintenance-free system - wear-free components
  • Clamping-table at convenient working height for operator-friendly testing
  • Remote control with color display showing measurement channels, machine and test status; also used for machine set-up
  • Easy to operate via testXpert II and testXpert Research test programs matched exactly to the testing situations
  • Large range of standard tools and fixtures

HC25 Compact servo-hydraulic testing machine - new design

The compact layout of Zwick's servo-hydraulic HC load frames has proved very popular. Now this testing machine is available in a new design with integrated hydraulic power-pack.

Application

Fatigue tests on materials specimens and components

Key features

  • Compact servo-hydraulic testing machine with low-noise hydraulic power-pack incorporated into machine base.
  • Hydrostatic-bearing hydraulic actuator mounted in upper crosshead.
  • Stiff two-column load frame with mechanical or hydraulic crosshead adjustment.
  • Hard-chromed T-slotted platform for component testing incorporated into machine base.
  • Hydraulic BOW grips, Fmax 25kN
  • Zwick load cell with integrated accelerometer.
  • testControl II digital measurement and control electronics with 10kHz control frequency and 24-bit resolution.
  • testXpert Research testing software.

Advantages and benefits

  • Extremely compact, space-saving testing system with small footprint.
  • Extra-quiet low-noise power pack.
  • Extra-stiff two-column load frame with integrated T-slotted platform for flexible component testing.
  • Uses hydrostatic-bearing, sealless actuators for virtually frictionless and maintenance-free operation.
  • Suitable for 10kN and 25kN axial actuators
  • T-slotted platform is ready for use with an alignment unit to enable exact load-string alignment for special applications.
  • Remote control with integrated Emergency STOP allows convenient set-up and control of test sequence, together with display of measurement channels and machine and test status.
  • Easy to operate via testXpert II and testXpert Research test programs matched exactly to the testing situations.
  • Large range of standard tools and fixtures.

25kN alignment unit for HC testing machines

Application

Alternating load tests on aluminum casting alloys

Key features

  • Alignment as per ASTM E1012 in HC testing machine also
  • For alternating-load HCF or LCF tests
  • Can be assembled/dismantled on the T-slotted platform

Advantages and benefits

  • Enables alignment adjustment in HC testing systems.
  • Component tests still possible; alignment unit can be removed.
  • Alignment measurement integrated into tXp III. Electronics can be operated via machine PC.
  • Static and dynamic tests on fiber-reinforced composites or strain-controlled alternating-load tests on metals with demanding alignment requirements can be performed using HC testing systems.

100kN collet grip for alternating load fatigue tests

Application

Strain-controlled fatigue tests as per ASTM E606 - LCF

Key features

  • High-precision clamping of round specimens with very high alignment reproducibility.
  • For HCF or LCF tests on round specimens.
  • Suitable for use with short furnaces or induction heating systems with integrated cooling of specimen grips.

Advantages and benefits

  • Very high alignment reproducibility when gripping specimens due to grip inserts matched to the specimen diameter.
  • Because the specimen is gripped all round in the collet the clamping stiffness is the same in all directions. This ensures that the specimen does not deform in a particular direction under compression loading, leading to an undefined flexural loading.
  • During high-temperature tests only the specimen is heated. This means that the stiffness and alignment of the specimen clamping are maintained at high temperatures also.

Operating concept: servo-hydraulic load frame with specimen grip control system

Application

The safe, reliable, operator-friendly testControl II operating concept applies to all servo-hydraulic load frames.

Key features

  • Use of display-equipped remote control for crosshead adjustment
  • Safe, easy, reliable operation of servo-hydraulic testing system
  • Uniform operation of all testing systems with testControl II

Advantages and benefits

  • Efficient, convenient handling when used as operating panel for actuators, load frames and specimen grips.
  • Fast, high-precision positioning of actuator via rocker switch and integrated thumb-wheel.
  • Flexible operating position for large load frames. Display indications allow excellent monitoring when installing specimen grips or inserting specimens.

Pneumatic wedge grips up to 10 kN for fatigue tests in temperature chambers

Zwick's new pneumatic wedge grips impress with optimum interaction of all system components, ensuring reliable test results combined with fast, easy handling.

  • Convenient, intuitive operation via remote control unit. Customized settings can be conveniently configured and managed in testXpert.
  • Fast, simple clamping of force-sensitive specimens via monitored force control during the closing process.
  • Stepless adjustment of exactly reproducible gripping force via the testing software.
  • Flexible positioning (0°, 45°, 90°) of the grips in the test frame via standardized flange connection.
  • Low weight plus compact design simplify handling, allow large travel distances and ensure short heating and cooling times in the temperature chamber.

10 kN materials testing machines with roboTest F robotic testing system

Application

Automatic tensile tests on films/foils

Key features

  • roboTest F robotic testing system with two testing machines
  • Z010 10kN materials testing machine including pneumatic grips
  • Revolving magazine for up to 200 non-rigid specimens
  • Automatic removal of specimen remains
  • autoEdition 2 automation software

Advantages and benefits

  • Robotic testing system requires no supervision (e.g. during breaks), allowing high specimen throughput.
  • Subjective influences (hand temperature/moisture, off-center or angled specimen insertion etc.) are eliminated for high test-result reproducibility.
  • Low per-specimen testing costs - robotic testing system covers costs within approximately two years.
  • Modular design of the robotic testing system allows manual testing whenever required.

10kN and 5kN materials testing machines with roboTest R robotic testing system

Application

Automatic tensile and flexure tests on plastics

Key features

  • roboTest R robotic testing system with two testing machines
  • Z010 10kN materials testing machine including multiXtens extensometer and pneumatic grips
  • Z005 5kN materials testing machine including automatic flexure test kit and flexure transducer
  • Drawer magazine capable of holding up to 840 specimens
  • Automatic cross-section measuring device
  • autoEdition 2 automation software

Advantages and benefits

  • Robotic testing system requires no supervision (e.g. during breaks), allowing high specimen throughput.
  • Subjective influences (hand temperature/moisture, off-center or angled specimen insertion etc.) are eliminated for high test-result reproducibility.
  • Low per-specimen testing costs - robotic testing system covers costs within approximately two years.
  • Modular design of the robotic testing system allows manual testing whenever required.

autoEdition 3

autoEdition 3, Zwick’s new generation of software for automated testing systems, builds on experience gained with earlier versions while offering useful new functions.
The focus of the new features available with autoEdition 3 is on "Industry 4.0" and medical engineering requirements.

  • Comprehensive options for networking with higher-level databases and for integration into the laboratory network.
  • Advanced notification functions, e.g. via e-mail or text messaging.
  • Easy remote access to automated system, e.g. via tablet or smartphone.
  • Customized user management with ability to integrate into an LDAP environment.
  • Reliable trail outputs for documentation of system use and status.
  • Easy operation of testing system via improved interface integration with testXpert III.

testXpert III - intuitive and workflow-based right from the start!

testXpert III is the result of close collaboration with users in materials testing and the experience gained from over 30,000 successful testXpert installations. From the very start, users can easily and intuitively navigate testXpert III. The clear, logically structured workflow guides the operator all the way through test preparation, performance and results analysis. testXpert II is a workflow-based software that keeps training time to a minimum and makes testing efficient and reliable.

Rapid familiarization with user management
Intelligent user management means you can define different user roles or import user roles direct from Windows accounts via LDAP. Users see only what is important to them so they can focus on the task at hand right from the start.

Intuitive, efficient operation
The intelligent test configuration wizard shows the operator which test parameters still require to be configured and automatically checks them for plausibility. This is backed by clearly identifiable visual association and logical grouping of related contents.

The safest testing system on the market
The unique System Configuration Builder makes it possible to define exactly repeatable test conditions and offers maximum safety for user and testing system All relevant machine and safety settings, including crosshead position, fixture separation and sensor configuration, are saved and are assigned to freely definable system configurations. testXpert III always knows HOW, WHERE and WITH WHAT you must test.

Automated data import and export
testXpert III reduces input errors, increases efficiency in the test lab and communicates with every IT system through automated importing and exporting. In addition, all series and exports can be viewed in secure mode. This prevents users from making subsequent modifications to the data and verifies the test.

Traceable manipulation-proof test results
testXpert III logs all testing system and system settings and guarantees answers to the question "When does who do what, why and who is responsible?". The combination of tools available in testXpert III ensures that test results are protected from manipulation at all times and that all changes and test results are traceable.

Optical extensometers - new cameras deliver a higher image rate plus even greater test result accuracy

The crucial advantage of extensometers featuring non-contact measurement is that they can be used right up to break without risk of damage, even with specimens which are critical in this respect. Because they make no contact with the specimen, optical extensometers have no influence on material characteristic values. Specimens are measured using two to four-camera measuring systems. High-resolution cameras incorporated into the new videoXtens complete systems ensure a higher image rate and even greater test result accuracy, while additional information regarding the specimen, such as transverse strains or strains over the specimen surface, is provided by various software options. Software options such as Strain Distribution or Test ReRun enable every specimen to count - even if the break occurs outside the gauge length.

Non-contact complete systems – simple, with clear application matching
The optical extensometer portfolio is as varied as the applications themselves. We have matched the new videoXtens complete systems to clearly defined applications in line with their technical advantages. This greatly simplifies selecting the right system.

For example, videoXtens for testing elastomers withstands whipping specimens without damage, possesses a high measuring range and allows modulus values to be determined in the initial range. Alternatively, videoXtens Array for testing reinforcing steel enables breaks outside the gauge length to be evaluated (Strain Distribution option), saving time plus the cost of additional specimens. Moreover, no specimen marking is required; virtual gauge marks are set via pattern recognition.

New clip-on extensometers - perfect for metals and rigid plastics

These new clip-on extensometers are specifically designed for tests on metals, plastics and composites, with the focus on reliable test results and ease of operation.

Accuracy plus outstanding resolution
The clip-on extensometer satisfies Accuracy Class 1 to EN ISO 9513. It is heat-resistant and ideal for closed-loop strain-rate control as per ISO 6892-1 (2009) Method A (1) for metals and ASTM E8 - 09 Method B. It can also be used for testing rigid plastics to ISO 527.

The biaxial clip-on extensometer can be used specifically for determining change in length and width of metal or fiber-reinforced composite specimens and is also suitable for determining in-plane shear strength (IPS) and Poisson's ratio.

Operator influence minimized for reproducible test results

The clip-on extensometer can be attached to the specimen quickly and securely using one hand. Automatic locking and unlocking of the set initial gauge length eliminates operator influence and ensures reproducible test results.

Reliable measurement of the smallest deformations
The Clip-on Compact extensometer features compact design, making it ideal for testing even the smallest specimens, while its high resolution and outstanding linearity allow accurate measurement of even the smallest deformations.

Instrumented indentation test with the new ZHU/zwickiLine

More than just hardness
Zwick Roell's investment in new technologies for hardness applications has enabled an expansion of these applications, backed by enhanced operator-friendliness. The hardness testing methods most frequently used in practice are the classical Rockwell, Brinel and Vickers methods. The modern instrumented indentation test (also known as Martens hardness, ISO 14577) also continues to gain in importance and is used increasingly frequently, particularly in research and development and in industrial applications, as it supplies other parameters for determination of material properties, in addition to the hardness value. The result obtained with the test is the continuous force/indentation-depth curve during the complete test cycle; it can be used regardless of material. ZHU/zwickiLine with testControl II electronics can also be used for materials testing (e.g. tensile tests) as well as for hardness tests.

Typical applications for ZHU/zwickiLine

  • Hardness tests on metals: instrumented & cyclic indentation tests, together with classical hardness tests (Vickers, Rockwell, Brinell)
  • Ball indentation tests on plastics (e.g. ISO 2039 -1)
  • Cyclic compression tests on paper or ceramics
  • Vickers test on ceramics

Type ZHR8150CLK Rockwell hardness tester with closed loop technology

Achieve reliable test results with the ZHR8150CLK hardness tester - for more than 30 different depth-measurement applications, including Rockwell and ball indentation hardness

Wide range of applications
Load application with closed-loop control enables hardness tests using only one instrument for a wide range of applications including:

  • metals – ISO 6508 & ASTM E18
  • plastics– ISO 2039-1 & 2, ASTM D785
  • carbonaceous materials - DIN 51917
  • laminated floor coverings - ISO 24343-1

Optimum test sequence
The production-oriented Rockwell hardness tester with special nose-mounted indenters allows hardness testing even at difficult-to-access locations. The automatic test sequence, depth-measurement system with 10nm resolution and automatic conversion to alternative hardness scales save time and guarantee a high level of accuracy and repeatability. Rugged construction with zero-backlash ball-bearing-mounted lead screw and simple operation provides the ideal requirements for production-line use.

And the results?
Export your test results to testXpert III via USB and experience the benefits of intelligent report creation and easy database connection.

Zwick's Materials Testing Laboratory delivers precise, efficient, standard-compliant testing – all types!

Zwick's Materials and Component Testing Laboratory performs quasi-static, cyclic and dynamic impact tests to customers' order. From preparation of the specimen material, to testing, to evaluation and analysis of test results, the Zwick Testing Laboratory offers an expert materials testing service. Zwick's testing laboratories are equipped with the latest testing systems for a wide range of tests on all types of components and materials. You too could benefit from our state-of-the-art testing systems and our laboratory staff's long-term experience.

  • Fast, standard-compliant testing to bridge your capacity bottlenecks
  • Cost-flexibility through precise test results and efficient test performance
  • Cross-validation to safeguard your test results
  • Design and modification of test devices
  • Long-term experience and solid expertise in all sectors and applications, including automotive, mechanical engineering, plastics, composites, medicine etc.
  • A comprehensive testing service, now including large and oversized components

Zwick Service - expert and reliable

Zwick provides individually tailored services and provides support through the entire life-cycle of your materials testing machine. We carry out checklist-based inspections and calibrations on over 10,000 testing machines annually and ensure your testing machine is able to deliver reliable results at all times. In addition, the ZwickAcademy offers a comprehensive range of training courses to ensure safe, efficient operation by all users. And if any problems or questions should happen to arise, our customer support team is there to provide expert advice on hardware and software issues.

  • Expert, professional, checklist-based maintenance and inspections
  • Comprehensive, internationally accredited calibration portfolio
  • Interesting and wide-ranging training program delivered by competent, experienced trainers
  • Hotline support from qualified and experienced service engineers
  • Zwick also offers appropriate service packages for repairs, machine relocation, qualification and alignment.
Cats3

Dynamic modernization with Control Cube – the flexible, expandable option for modernizing servo-hydraulic systems

With ControlCube, Zwick can now modernize servo-hydraulic systems regardless of manufacturer. The world’s smallest servo controller is the perfect solution for tests on materials, components and complete products.

  • Cubus covers a multitude of test methods, including advanced ramp tests, fatigue tests, block programs and the reproduction of measured data.
  • Control Cube is extremely versatile in use - from simple cyclic tests to complex multiaxial test benches.
  • Flexible and expandable with a wealth of functions
  • Intuitive operator interface featuring simple, clearly presented information.
  • Plug and play
  • Easy system configuration
  • Clearly structured software for ease of operation

High-temperature testing

High-temperature testing includes applications such as quasi-static tensile, compression and flexure tests, together with creep, creep relaxation, creep crack growth and creep fatigue tests. Testing systems which are flexible in use are therefore of particular importance for applications in this field.

Increasing demands, particularly in the field of strain measurement, have led to a considerable expansion in the use of non-contact extensometers. Areas of use include micro-specimens, long specimens such as pipes, brittle-fracturing specimens such as titanium aluminide, sensitive specimens such as ceramic honeycomb structures, high strains and temperatures over 1,200°C.
In addition, extensometers are required to be capable of being used at both room temperature and high temperatures wherever possible. videoXtens and laserXtens are an ideal match here.
Increasing requirements with regard to temperature range and workplace safety call for new solutions. These are illustrated by a ceramic load string for tests over 1,200°C and the new high-temperature creep furnace.

To achieve reliable test results at high temperatures, special temperature measurement and control requirements must be taken into consideration in addition to provision for room-temperature testing.
Temperature measurement and control must be precise, repeatable, reproducible and traceable. Solutions plus explanations will be on display.

Highlights

  • High-temperature tests on sensitive micro-specimens
    Materials testing machine with alignment device, short stiff load-string, 3-zone short furnace and non-contact laserXtens Compact
  • Flexible testing system for tensile tests at room temperature and high temperature
    Materials testing machine for wide range of specimens with short-clamping-length hydraulic grips (RT), self-aligning load string (HT), 3-zone furnace and non-contact laserXtens - can be used at room temperature and high temperature
  • Materials testing machine for HT tensile tests with an inductive heating system for rapid, monitored heating and cooling cycles.
    Additional equipment: laserXtens Compact non-contact extensometer
  • Reliable test results at high temperatures plus new components
    Kappa LA patented lever-arm creep testing machine for creep applications
    owith new high-temperature creep furnace with flexible accessory interfaces and optimized workplace safety provision
    owith ceramic load string for air temperatures over 1,2000°C
  • equipment for "Reliable test results at high temperatures"
    Flexible testing system for all current creep applications
    Kappa SS-CF patented electromechanical creep testing machine equipped for creep fatigue applications with hydraulic and mechanical grips and non-contact videoXtens.

Building Materials Testing

ToniPERM Expert
The Blaine apparatus (Dyckerhoff System) has been significantly upgraded with new electronics and intuitive touchscreen operation. Temperature measurement of the air stream via the measurement cell allows correct calculation of the Blaine value. In addition, multiple calibration values for different reference materials can be stored with an interpolation curve and used for calculation. These improvements have resulted in higher result accuracy and easier handling.

ToniCal SoftXpert
We are pleased to present a new generation of software for the ToniCAL heat-flow calorimeters which allows early interpolation of the 28-day hydratation heat and provides additional information on processes during strength development via mathematical analysis of the curve shapes (derivation).

ToniMIX ViscoExpert
The Toni Technik mixer with viscosity measurement now additionally features a freely programmable user interface. This option enables customized mixing and dosing processes for special materials or mixes which can then be stored for reproducible repetition

ToniTROL II
ToniTROL II with testXpert III is available with functions Force; Travel and Deformation Control for corresponding test sequences.
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