Challenge the Naysayers in Engineering Design

The engineering design field has witnessed a multitude of profound changes and emerging trends in the past decade with digital transformation in full swing. As companies harness available technologies and leverage design innovation and products to enhance business capabilities and customers’ experience, engineers are facing new and complex challenges to adapt processes and ensure product reliability.

This rapid growth of technology is reshaping the way engineers design and develop equipment as they look further into the future to ensure compliance for quality testing of products to meet both existing and evolving standards.

Thanks to this, the role of engineering redesign and quality testing has become more crucial than ever. And while some may think these new challenges merely pose stumbling blocks, we see them as ways to improve the role of materials testing across all applicable industries.

Maintain Design Integrity

Engineers are confronting more instances of solving design problems due to the rapid speed at which technology is advancing. For materials testing, this presents some unique challenges, as engineers also must meet specific industry standards for safety, quality and production requirements. There is a careful balance between the innovation happening within their production environments and the need to adhere to existing industry standards.

Lexi Patania, mechanical design engineer for Tinius Olsen, noted, “Some may believe that, with new technologies comes new machinery, and that is true to an extent. But many aspects of the development and testing process can be redesigned and adapted to meet new technical challenges.”

She goes on to explain, “There are often scenarios, where the dimensions of a specimen, or it’s expected force, may fall outside the range our normal test fixture accepts. That involves adapting the current fixture to meet the required dimensions and load capacity, as well as any other design constraints. We do a lot of that, but we’re also very involved with developing new designs to meet the growing complexities we see in our customers’ applications, while maintaining much of the existing test infrastructure.”

New Challenges Mean Opportunities

Patania explained a recent project for hardness testing, which typically uses a flat or v-anvil fixture when testing typical Rockwell specimens.

This particular application, though, involved a specimen with complex geometry and several different testing locations along its length and rotational axis, all of which needed support, directly through each of the test points. Because each test point had different geometric attributes, and the sample must be fixed when load is applied, the fixture needed to be adaptable in one linear and one rotational motion, and lock in place at all 16 positions.

She continued, “We were able to develop a fixture that tests 4 points, turns once to accommodate testing of the other 4 points, and is interchangeable with a similar fixture to obtain the remaining 8. This design requires minimal operator effort, pinpoints exact test locations, and provides the results needed across the entire specimen in a way that had not been done before. It’s exciting to solve these challenges for our customers.” Identifying and solving testing problems according to set industry standards is a large part of the innovation at Tinus Olsen. (Figure 1)

Consistency Ensures Reliability in Innovation

Standards are essential to fueling innovation as well as maintaining a level of confidence in products. The integrity of broad-based frameworks establishes accurate and workable principles for technology adoption and interoperability. The research and development (R&D) stage, especially, plays a key role in meeting the constant innovation of engineering as well as adjusting standards to meet changes.

As ASTM notes, testing standards provide guides for the proper procedures employed in the determination of the physical, mechanical and metallographic properties of certain materials…to allow metallurgical laboratories, manufacturers, and other producers…to examine and evaluate such materials for strength and quality to ensure safety towards their end-use.

Adopting Reengineered Solutions

The critical role that standards from organizations like ISO and ASTM play in the materials testing industry is undisputed. For decades, these standards have served as our barometer of product quality and customer assurance. Our next step as an industry is to facilitate the alignment of the standards with the engineering redesigns being developed that are solving the new challenges we are seeing in manufacturing and product testing. (Figure 2)

Engineering redesign has become more prevalent in the past few years as supply chain issues have grown more prominent. By practicing engineering redesign tactics, the industry can keep up with growing technologies, while still providing quality products to consumers. Have an engineering challenge you want us to take on? Check out our Service & Support page for your local contact.

New Extensometer Technology Facilitates Better Materials Testing

With tight timelines and even tighter budgets, the pressure to deliver high-caliber products has never been more important. In a world where quality and reliability can make or break a company’s reputation, cost-effective testing techniques that improve testing efficiency and benefit from modern technological advancements are the ones that will give R&D, engineers and test facilities a distinct advantage.

Since the standardization of extensometry in the 1950s, the use of an extensometer—a sophisticated ruler used to measure displacement or strain on the surface of a test piece—has not changed significantly. However, it has become evident that this testing methodology needed a boost to keep pace with modern applications, where other computing mechanisms have been built into materials testing systems.

Increased Test Efficiency

The introduction of new optical extensometer technology has made traditional, mechanical tools nearly obsolete. It uses intelligent non-contact, high-accuracy measurement techniques to eliminate the common challenges of traditional contacting and non-contact extensometers, while also offering some distinct advantages.

For those looking to take an easy, first step toward automating their existing materials testing process in order to maintain consistency in test performance, the new Vector Extensometer (Figure 1) reduces operator involvement, decreasing manual errors in calculation or calibration as well as simultaneously measure longitudinal and transverse strain.

This self-contained, plug-in-and-power-up precision system eliminates all the tricky and cumbersome set-up options associated with other optical extensometers and removes the need for multiple PCs and interface equipment.

Using adaptive Artificial Intelligence (AI) coupled with optical hardware, Vector reduces testing time and is ideal for complex environments, such as assessing extremely fragile specimens as well as small and non-uniform specimens, measuring strain through failure or operating in harsh or dimly lit applications.

Tackling Common Trouble Spots

For each trouble area that extensometry has encountered in the past, now there’s an easy solution.

Poor grip on a specimen? Vector is non-contact. Worn edges? No problem, Vector is laser-enabled. Improper length? It is compliant with ASTM E83. The need for manual calculation? Measurements are now computerized. Worried about accuracy and the possibility of improper data collection? AI-based capture eliminates that risk.

Vector addresses it all, clip sensitivity, dulled edges, physical marking, manual calibration fluctuation, non-uniform specimens, synchronized force and strain data. It delivers quality results in every test. (Figure 2)

Adoption and Usability

Setup is straightforward, so adding it to existing equipment is simple. And what is even better, there are no special skills required to run it. Everyone from new hires to company veterans can set up the machine and start running tests in no time.

Vector reduces risk because it is very hands off and streamlined, with processing power contained within the unit itself. Users don’t need a separate PC to process and manage the data. The system pre-processes it and sends direct to the main PC.

This cutting-edge technology is the very latest in digital extensometry, enabling synchronized force and strain data in real-time, with no lag.

Optimal ROI

This step-change in digital, data-driven materials test processing is seen across a wide range of industry sectors, with Vector meeting or exceeding ISO 9513 Class 0.5 and ASTM E83 Class B1 standards. Vector provides optimal overall ROI, thanks to its streamlined testing process, accurate results in every test scenario and the elimination of consumable parts that need replacement.

Accuracy, resolution, data rates, control, precise adherence to test standards, calibration, measurement of uncertainty and traceability – this new advancement in extensometry can handle them all.

To learn more about available Vector models and how new optical extensometer technology facilitates better materials testing, download our whitepaper Modern Extensometry for a Data-driven World.

Automotive OEMs Improve Materials Testing ROI With In-house Infrastructure

Materials testing is an integral part of the automotive industry. It provides quality assurance by ensuring that vehicles, including all their components, are safe and reliable, while also meeting the regulatory standards required by the federal government. Although third-party testing centers are a popular choice among OEM suppliers, implementing an in-house materials testing system can quickly provide a better, and more significant, return on investment.

Recent Effects of Recalls and Safety Concerns

While maintaining profitability is a key area for the stability of any business, in automotive component manufacturing, trust among the consumer and the automakers themselves is worth more than its weight in gold. Recent years have seen an increase in high profile instances of recalls, defects and unsafe operating environments that have eroded consumer confidence, putting more emphasis on the value of a company’s reputation and ability to provide reliable, safe automotive systems. (Figure 1)

Sending parts out for third-party inspection and verification is one method of quality control, but more OEM suppliers are evaluating the benefits of an in-house materials testing system that affords them the opportunity to better manage yield and inventory, with speedy responses to production defects and better oversight of the actual production process.

Improving ROI and Consumer Confidence

Investing in an in-house materials testing system empowers OEMs to improve product quality, innovate effectively and maintain competitiveness in an industry that is not only extremely demanding, but also regulated by standards, including ISO, ASTM and ES. While the initial investment may seem higher than a weekly shipment to an off-site testing facility, the long-term savings can be substantial, with a return on investment seen quicker than one might think:

Reduction in Testing Costs: OEMs avoid immediate recurring costs, like testing fees, associated with hiring third-party testing services. Over time, in-house testing equipment reduces the cost and time associated with sending parts out for testing.
Faster Time-to-Market: An in-house infrastructure allows for rapid testing and prototyping, in turn creating faster product development cycles. OEMs can respond more rapidly to design changes or new requirements, reducing delays in the production process. Turn-around times are faster, too, since materials can be tested as needed.
Custom Testing Capabilities: Developing testing methods that specifically address unique materials and performance needs, like harness, metal and corrosion testing, means OEMs also have the ability to experiment with new materials and technologies that could lead to new and more innovative products. Continuous improvement is possible when testing in-house because it allows OEMs to focus on specific materials and processes, refining testing strategies over time while working to enhance product development and innovation.
Data Ownership: With better control over testing data, the analysis and integration OEMs can implement into the development process helps to improve product quality and performance. Software-based management tools, like Tinius Olsen’s Horizon platform, provides computer-assisted data acquisition and machine control that collects, analyzes, graphs and stores data. It can also provide control over testing operations. (Figure 2)

A Streamlined Process: In-house testing encourages collaboration between a variety of different departments, including testing, engineering, and production, to create a more efficient workflow as well as help avoid delays and scheduling conflicts that often happen when using an outside testing facility.
Quality Control: Maintaining consistency and direct oversight of the testing process and protocols ensure that testing standards are adhered to, an important factor in the automotive industry. This leads to higher quality materials and components with fewer defects and recalls, which significantly impacts profitability. It also can lead to longer-lasting components and parts, which improves a brand’s reputation and customer satisfaction, translating into increased sales.
Ease in Scalability: Today’s materials testing systems are designed to scale with the needs of an OEM quickly and efficiently. This allows manufacturers to accommodate increased testing and production demands without a significant increase in cost. Some systems even perform multiple test scenarios within the same compact system footprint.

Before you look to invest in an in-house testing system, take stock of your most critical testing parameters. Equipment, like the Tinius Olsen universal testing machines, are designed to perform quality control tests on raw materials, like metals, polymers, textiles, rubbers and adhesives. A horizontal tensile testing machine tests for tensile strength, along with elastic modulus and corrosion resistance, in materials like alloys, composites and plastics and an indentation hardness materials testing machine can quickly and accurately determine the hardness value of metals, components, large parts and small precision parts used in cars. (Figure 3)

While the upfront costs of purchasing materials testing machines can seem overwhelming, the benefits and long-term advantages, including greater quality control, speed, flexibility, customization and security, align closely with an OEM’s goals of quality, efficiency and innovation. This can lead to a more favorable ROI in the long run and helps maintain a competitive advantage in this demanding industry.

Two Test Systems, One Software Platform

Technology innovations in materials testing aren’t just providing better data analytics, they are also providing improved testing efficiencies. In an industry predicated on long-standing industry standards that dictate the parameters of test results—including precision, repeatability and accuracy—we’re still finding ways and opportunities to improve testing efficiency across the industry and focus on improvements, where it makes sense.

Because the standards themselves don’t change much from year to year, we can seek other methods of process improvement. Digitizing test information using updated tools, like enhanced software packages, has allowed users to collect, manipulate, analyze, graph and store data in ways that previously were just not feasible. This ability to make testing data more actionable gives us deeper insights into our materials testing operations.

Streamlined Process Through Software Advancement

Prior to the use of intuitive software platforms, a computer system was typically needed for each testing set up. That also meant space was needed for each machine, test system, etc. Moving data analysis into a streamlined software process not only helps move our industry forward, but it’s also transforming how we can do things with better data insights and more efficient reporting, while enabling a smaller test system footprint on the testing floor. (Figure 1)

Fig. 1: Advancements in software platforms are providing a more holistic materials testing environment that both improves production and saves floor space within a facility.

Where space is at a premium, like in a lab where there is already quite a bit of existing infrastructure and the constant need to upgrade, with limited space to do so, materials testing software has completely changed how things are done. In the case of Horizon software from Tinius Olsen, there’s more than just space-saving benefits; it has the ability to manage both the test procedures and the automation, making data easily accessible, for everything ranging from R&D to charging and analysis functions of QC testing.

A Gamechanger On the Testing Floor

A recent application at a global polymer matrix composite manufacturer put Horizon’s capabilities to the test. An automated materials testing system using the software was built so that two independent automated tests – tensile (ASTM D638) and flexure (ASTM D790) – ran simultaneously on the same machine. The reduced scale of the system in footprint alone enabled a more efficient testing environment, and the physical assembly was complemented by enhanced digital data exchange across internal processes, which included a bar code led data flow, customized results, alerts and system status. (Figure 2)

Fig. 2: Running one software platform across multiple test environments can reduce the materials testing footprint needed, especially critical for upgrades in existing facilities.

Key to this testing set up is the robotic arm, which accesses the specimen rack and test frame for both machines, all running on a single Horizon software platform. Through just one automation cell, the two tests are performed, streamlining data, reducing latency and improving materials testing results.

Overall Operations Improved

Whether you’re controlling and gathering data from multiple melt indexers, hydraulic tensile testing machines, or electromechanical testing machines that are performing tensile, compression, flexural, tear, peel or other tests, Horizon can run all the tests and gather all the information in one place. In addition, the software features a recall function that enables you to add key data that is either not available or missed. All digital data is streamlined and easily accessible.

Once all data has been gathered, the software’s result editor and output editor can consolidate all data that has been generated into customizable reports, depending on what type of analysis you or your customers may need. Multiple graph types can be applied per test, like stress vs. strain, or load vs. time, and reports can be distributed across one PC, multiple PCs, or across a network for easy multi-team access, keeping everyone on the same page. (Figure 3)

Fig. 3: Intuitive software platforms, like Horizon from Tinius Olsen, enable streamlined data processing and more advanced results and analysis.

Confidence In Your Testing Methodology

If your testing regime follows a quality control analysis to a variety of international standards, be sure your software includes a built-in test method library built that enables you to select test methods that have been written in accordance with your applicable industry and international test standards.

The ability to customize the test setup using a standard as a template and a configurable database that facilitates sharing across several computers on a company’s network are also important aspects to consider, as this will allow the testing programs and testing data to be used by multiple systems.

As part of the software’s development process, Tinius Olsen took the best features of its existing software, including Test Navigator, QMat and EP600, added a host of report writing and data manipulation capabilities and created Horizon, now one of the most advanced software platforms for materials testing.

As we move forward as an industry, we should continue to develop the means to innovate the materials testing process by focusing not only on testing machines, but on the holistic process of our testing environments.

Sustainable Alternatives Gain Validation Through Materials Testing

The past few years have shown us that the world around us is finite and fragile. And we all play a part in its sustainability. There has been a push across several industries to develop inventive, forward-looking products and technologies, while maintaining a better balance with the environment for long-term global health.

With innovation comes the unknown. Will a newly developed material stand up to the defined ASTM or ISO standards or will the use of a different material in an existing application meet the required industry standard benchmarks? Standards exist to ensure product safety and quality, which is all for the benefit and protection of the end user.

Confidence in Material Innovations

As an industry, we are tasked with maintaining a level of confidence in the products and solutions being delivered, and standards are an important aspect of that. There are many promising examples of sustainable products that incorporate recyclable or biodegradable materials and also support an eco-friendly environment. But to be able to confidently put these innovations into the mainstream, companies still rely on materials testing to known industry standards and specifications.

Material testing provides the insight to gauge the useability of certain materials and products in specific environments. And in the world of eco-friendly material innovation, it has helped lay the groundwork to develop solutions beyond just delivery of a product, but also to help combat climate change, to increase types and quantities of materials that can be recycled, and ultimately open doors to innovations that are solving some real-world challenges.

Recycled Glass Aggregate

The collapse of I-95 in Philadelphia, PA seemed, at first, catastrophic. Initial calculations framed the road closure in years, then possibly over several months. So who would have thought that in a mere few weeks, this massive roadway connecting a large swath of the eastern United States would be up and running after such an epic event, using a sustainable material made from glass.

Recycled glass aggregate is not new. Formed by crushing glass into a powder, blending it with a foamy slurry, heating it and then breaking it into briquettes, the crushed aggregate is used in a number of construction applications, including as backfill or in roller applications. The size, shape, density and strength of the aggregate all affect its long-term performance in pavement and structures.

Testing of the ultra-lightweight foamed aggregate is critical to prove its efficacy and ensure it has the strength needed to bear the weight and force of heavy-duty construction. It also confirms that the aggregate is composed of a good mix of chemicals and materials that can compact to and withstand a certain force. Thanks to testing performed using Tinius Olsen equipment, the company developing the aggregate already had the results and data to know this aggregate could serve as the backfill for the temporary lanes constructed along the highway corridor.

Figure 1: Testing of the aggregate is carried out with Tinius Olsen equipment.

Sustainable Wool Rope

Seaweed farming itself is not only a sustainable source for fertilizer, bio-ethanol and livestock feed, but it helps negate carbon and nitrogen levels in the ocean as well as provides a healthy ecosystem for marine life. So the fact that non-recyclable, everlasting polypropylene rope is laid on the sea floor to grow the harvested seaweed counterbalances the environmentally-friendly aspects of growing a renewable resource. And this plastic rope is washing up on coastlines across the globe, rubbing against rocks, resulting in a hard plastic crust coating the coastlines.

But what if the rope was made of biodegradable wool that itself is sustainable and renewable. Would its physical properties still hold up as needed in the corrosive saltwater environment? Tinius Olsen is helping to answer this question.

Manufactured in a range of diameters, from small lengths to full coils, all of the wool rope currently produced is from local farms and craftspeople in the United Kingdom. But this paradigm shift for seaweed farming needs validation and is being accomplished through materials testing. By relying on proven equipment Tinius Olsen is helping to identify the proper breaking strain as well as design the special grips needed to hold the rope for proper testing.

Figure 2: The sustainable rope is used to farm seaweed and shellfish

Testing of Eco-friendly Innovations

In the world of materials testing, manufacturers turn to industry standards to enable them to validate, qualify and prove the viability of their products and raw materials. For materials pushing the envelope of what is known and acceptable, testing to a defined set of compliance levels becomes even more critically important.

Developing sustainable material alternatives and bringing them to market is no small feat. Testing validation is just one aspect of this process. Also of importance is a partner invested in the success of innovative product development and who has the technical knowledge and pedigree to deliver quality testing equipment to validate your product innovations.

Elevated Temperature Testing Validates Innovation in Additive-based Superalloy Manufacturing

Commonly used in extreme environments, such as in the aerospace, industrial and power generation markets, superalloys are a class of high-performance alloys with impressive mechanical strength as well as resistance to thermal creep and corrosion at high temperatures. Those in the materials science and engineering industries continue to develop increased performance capabilities and seek out new applications for these advanced materials.

Although used for decades, this type of material still requires specialized manufacturing techniques and produces a lot of wasted material, driving up costs in production. Additive manufacturing, which involves melting and fusing metal powders layer by layer, has emerged as a promising technique for producing the complex geometries of superalloy components as well as for reducing material waste during production.

Also known as 3D printing, this is still a relatively new, intricate process, and a deeper understanding of the performance and durability of the materials produced using this additive method is needed. (Figure 1)

Figure 1: The production of 3D printed high temperature superalloys is still a growing area, but elevated temperature testing can remove some of the unknowns in quality and reliability.

Studying Material Behavior

Those tasked with the production of superalloys have sought out new methods to further advance this additive manufacturing of superalloys and improve the performance and reliability of superalloy components in extreme environments. Answering the questions surrounding the mechanical behavior of these additively manufactured superalloys is a critical step in enabling this modern manufactured material to move beyond skepticism and play a critical role in high-performance applications.

Elevated temperature mechanical testing has always played a key role in the development of new materials that need to withstand extreme conditions, and additive-based superalloys are no different. By subjecting materials to elevated temperatures and mechanical stress, researchers have been able to identify the strengths and weaknesses of different materials, which has allowed them to develop new materials as well as identify ones that are better suited to specific applications.

Playing a particularly important role in the additive manufacturing of superalloys, elevated temperature mechanical testing allows researchers to study the behavior of these materials by simulating the high-temperature, high-pressure environments are often found in real-world applications. (Figure 2)

Figure 2: Today’s elevated temperature testing environments are total systems, comprised of the frame, chamber, sensors, specimen holders and software to help manage and analyze system data.

Why Elevated Temperature Testing?

Insights gained into the material’s microstructure and deformation behavior under different conditions can help identify potential weaknesses or failure modes in the material and inform the development of improved manufacturing processes or material designs. Proper elevated temperature testing can answer significant questions that will provide better performance and efficiency in the application of superalloys produced using additive manufacturing techniques:

What are the effects of different heat treatments on the mechanical properties of additively manufactured superalloys?
How do different alloy compositions perform under these temperature and stress extremes?
What strengths and weaknesses do these materials exhibit and how can each be used in specific applications?
With access to more accurate, repeatable data, what improved predictions can be made about a material’s behavior under extreme conditions?

Testing Today’s Superalloys

Modern elevated mechanical testing methods make use of advanced instrumentation and control technology, such as high-temperature furnaces and specialized testing frame and software configurations capable of applying precise loads, strains and temperatures to the specimens under test.

The development of these more advanced testing equipment and techniques has enabled significantly improved accuracy and repeatability, resulting in more precise insight into material behavior under extreme conditions. This has led to an increased understanding of material behavior, with researchers gaining insights into the fundamental physics of material behavior. Ultimately, new materials with improved properties and new production techniques can confidently be brought to market.

Testing standards also play a critical role in the testing of superalloys, so it’s important to note some of the more common ones used in elevated temperature testing. These include ASTM E21, ASTM E139, ASTM E145, ASTM E220, ASTM E1457 and ISO 6892-2, all of which define the test parameters, measurements and results to precisely characterize the response of material to determine its strength, performance and ensure quality to prevent failure in use as well as make informed decisions in terms of which materials to use for a given application.

Elevated mechanical testing continues to evolve and improve with new developments in materials science and technology. This materials testing method has helped to improve the safety and reliability of many critical systems, such as aircraft engines and nuclear power plants. By understanding how materials behave under extreme conditions, engineers can design systems that are better able to withstand these conditions without failing or causing harm to people or the environment. When working with new, innovative materials, such as additive manufactured superalloys, confidence in the process is just as important as confidence in the material.