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Testing Machines and Systemsfor Metals

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This catalogue provides an overviewof devices, machines and systemsof the Zwick Roell AG for the testingof metals in the correspondingindustries, research anddevelopment, test institutes andtraining centers. This is only a partof the extensive product portfolioof the Zwick Roell AG.

The Zwick Roell Group –More than a century ofexperience in materialstesting

Mechanical-technological testingis the oldest discipline of materialstesting. As early as in the 15th and16th century, Leonardo da Vinciand Galileo Galilei were alreadyconsidering the flexural stressingand the elastic behavior ofmaterials. In the course of timefurther know-ledge was obtained.In the middle of the 18th centurythe first testing machines finallyappeared in France.

Since the middle of the 19th centurythe company Amsler (formerly inSchaffhausen, Switzerland) hasbeen involved in materials testingand the company Roell & Korthaussince 1920. Since 1937 Zwick has

been building devices, machinesand systems for mechanical-technological materials testing.Long before that time, i.e.in 1876, Prof. Seger had alreadyfounded a chemical laboratory asa scientific-technological consultingcompany for the industry ofnonmetallic minerals. During the20th century, the present companyToni Technik has developed fromthese fundamentals and is nowconsidered a leading expert fortest systems for building materials.Excellent performances were alsosupplied by the company MFL(Mohr & Federhaff) — a companythat was founded in 1870. By theway, Carl Benz was one of theemployees.

Since 1992, these companies haveformed the Zwick/Roell companygroup.

The Zwick Roell AG .............................................................................................................................................. 2 Testing of metals – Special features ...................................................................................................................... 4 Standards and testing machines .......................................................................................................................... 6 Examples of applications with the testing software testXpert® ............................................................................... 8 Specimen preparation ........................................................................................................................................ 10 Materials testing machines * Field of application and basic concept .............................................................................................................. 11* Measurement and control systems ................................................................................................................... 11

* Load frames ..................................................................................................................................................... 12 * Drives .............................................................................................................................................................. 14 * Special Metals Testing Machine SP .................................................................................................................. 16 * Testing software testXpert® .............................................................................................................................. 17* Load cells ........................................................................................................................................................ 19* Specimen grips ................................................................................................................................................ 19* Tools for compression an bending tests ........................................................................................................... 22* Extensometers ................................................................................................................................................. 22Specimen handling systems ............................................................................................................................... 24Fatique testing machines .................................................................................................................................... 26Impact testing machines..................................................................................................................................... 28Creep testing machines ...................................................................................................................................... 29Ductillity testing machines .................................................................................................................................. 30

Hardness tester and testing machines ................................................................................................................ 31Modernization .................................................................................................................................................... 34

Services ............................................................................................................................................................. 35 Addresses .......................................................................................................................................................... 36

Photos front cover: DaimlerChrysler, Lloyd Werft, Hydro Aluminium, ThyssenKrupp

List of contents

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Roell Amsler GmbH & Co.KG atGottmadingen, Germany

Toni Technik GmbH at Berlin, Germany

In July 2001, the Zwick Roellcompany group was converted intoa stock corporation: the Zwick RoellAG. Part of this stock corporationare the companies Zwick, RoellAmsler, Toni Technik, Indentec Ltd.and Acmel Labo. These companiessupply an extensive program formaterials, component, andfunctional tests – from the manuallyoperated hardness tester up toa complex test system for theprocess-accompanying application.Since May 2002, Acmel Labo,French manufacturer of laboratorydevices for the cement, gypsumand lime industry is also part of theZwick Roell AG.

Zwick has many years of experience,combined with a multitude ofsupplied systems. This experienceis continuously supplemented bythe constant communication withour users. On this solid basis, thecompany supplies a wide range ofhigh-performance products – fromthe economical standard machineup to special versions and designsfor special test jobs. Modernmechanics, high-performanceelectronics and the application-oriented software are the prerequisitefor the versatility and the high”intelligence“ of these moderntesting machines and systems.

However, the services of the ZwickRoell AG go far beyond the supplyof products. Already in 1994 thecompany received the certificationaccording to DIN EN ISO 9001 andthus guarantees a consistently highproduct and service quality. Withaccredited calibration laboratories,the companies of the Zwick RoellAG are in addition entitled to verify

Headquarters of Zwick Roell AG and Zwick GmbH & Co. KG at Ulm, Germany

and to calibrate test systems and todocument that with internationallyrecognized certificates.

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Comparation of specific material properties

Material properties Metals Concrete Plastic mat.(without extreme values) (non-reinforc.)• Tensile and compr. strength, MPa 100 ... 2000 200 ... 500 20 ... 160• Young´s modulus, GPa 70 ... 210 15 ... 40 0.06 ... 6• Density (specific weigth), g/cm³ 2.7 ... 7.8 2.1 ... 2.4 1 ... 2

Testing of Metals –Special Features

Iron and steel, aluminium, copperand zinc and their alloys aremetals that are mostly used forthe production of appliances,devices, machines and buildings.The spectrum of their propertiesthus also determines the essentialdemands on testing machines.These are mainly the high strengthsand the high specific rigiditiescharacterized by the Young’smodulus of elasticity.

In case of a mechanical stress – asopposed to rubber for example –the high rigidity immediately takeseffect. This means considerableforce increases with very littledeformations, often less than thethickness of a hair, and an elasticresilience during the reduction inforce. Only if the force continuesto increase then a plastic, i.e.permanent deformation is overrulingthe elastic deformation. Specimensmade of very brittle materials(e.g. cast iron) and high-strengthsteels also break all of a suddenand nearly without any plasticdeformation once having reachedthe tensile strength. When usingtenacious metals, the (local) rigidityconsiderably decreases after havingexceeded the yield stress and caneven have values of zero or below(increasing deformation withoutforce increase or even with areduction in force).

The characteristic curve of a tensilespecimen made of deep-drawingsheet (gauge length L0 = 80 mm)clearly proves this. The elastic strainup to the yield stress is only approx.0.05 % resp. 40 µm, the plasticstrain however up to the break isnearly 37 % resp. 30 mm (which isalmost the 750-fold). This behaviourmakes particularly high demandson deformation measuring systems

which are to be used to determinethe Young’s modulus of elasticity,proof stress, uniform elongationand strain at break in the sametest (high resolution and long testtravels). Moreover, the measuringsystem must not be damagedduring specimen break.

Under the influence of the testforce, not only the specimen isdeformed, but there is also anelastic deformation of all testingmachine components (load frame,load cell, specimen mountings andspecimen parts outside the gaugelength) located in the flux of force.

Characteristic stress/strain curve of a tensile specimen made of sheet steel (see aboveillustration) and enlargement of the section until shortly after the 0.2 %-proof stress withillustration of the local gradient T via “virtual” measuring channel (see below illustration)

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Due to the large rigidity of thespecimens, the elastic deformationof the testing machine is mostlyclearly higher than the deformationof the specimen (up to more thanthe tenfold). The indirectdeformation measurement viacrosshead or piston travel or time istherefore practically impossible.

The crosshead and piston travelof the testing machine is accordingto the ratio between specimenand machine rigidity classifiedinto specimen- and machinedeformation. Therefore, the

Characteristic force/extension/crosshead travel curve of a tensile specimen made of sheet steel(tested with a Zwick Z100 materials testing machine with hydraulic specimen grips)

deformation speed depends notonly on the crosshead and pistonspeed, but also on the specimendimensions and the machineconfiguration. But the deformationspeed influencesthe characteristic values to bedetermined. Therefore acomparability of the test resultsof specimens with differentdimensions and of differentmachines can only be guaranteedif the crosshead or piston speedcan be controlled based on themeasured values of force anddeformation.

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Standards and Testing Machines

Contents Test standard Test means/Test device PageTest devices• Tensile, compression and bending ISO 7500-1, ISO 379, ASTM D 76,

testing machines ASTM E 4, EN 10002-4, ISO 9283,• Impact testing machines DIN 51222, DIN 51306, ASTM E23,

EN 10045-2, AFNOR A03-508Sampling and preparation• Specimen manufacture DIN 50125, JIS Z 2201, Machines for 10

ASTM E 8, DIN EN 10002-1 specimen manufactureTension, compression and bending tests• Tensile test at room temperature DIN EN 10002-1, ISO 6892, Materials testing machines 11

APJ 5L, JIS Z 2241, BS 18,ASTM A370, ASTM E 8

• Tensile test at elevated temperatures DIN EN 10002-5, ASTM E21, Materials testing machines 11• Tensile test at low temperatures ISO/CD 384 E, ISO 15579, Materials testing machines 11

ASTM E345• Tensile test on reinforced steel DIN 488, BS 4449, BS 4482, BS 4483, Materials testing machines 11

JIS 3112, ISO 10606, EN 10080• Tensile test on steel wire, strands e.c. SI 739, UNE 36065 Materials testing machines 11• Tensile test on strands and prestressing steel EN 10138, BS 5896, ASTM A416 Materials testing machines 11• Tensile test on metal foils ASTM E345, DIN 50154 Materials testing machines 11• Determination of hardening ISO 10275 Materials testing machines 11

coefficient (n-value)• Determination of the vertical ISO 10113 Materials testing machines 11

anisotropy (r-value)• Tensile test on weld seams DIN EN 895 Materials testing machines 11• Tensile test on chains DIN 22252 Materials testing machines 11• Tensile test on screws ISO 898 Materials testing machines 11• Shear test DIN 50141, LN 65150 Materials testing machines 11• Tests on tubes EN 10232, EN 10237, ISO 8491 Materials testing machines 11• Compression test DIN 50106, ASTM E9 Materials testing machines 11• Compression test on hard metals DIN ISO 4506, EN 24506 Materials testing machines 11• Bending test ISO 7438, JIS Z 2248, JIS Z 2204 Materials testing machines 11• Bending test (folding test) DIN 50111 Materials testing machines 11• Bending test on weld seams DIN EN 910, Materials testing machines 11

ASTM E190, ASTM E290• Bending test on sheet metal (0,05 ...1 mm thick) DIN 50151 Materials testing machines 11• Bending test on pipes and pipes lengths DIN EN 1023, ISO 84912 Materials testing machines 11• Method of Bond Test JIS Z 2248, BS 4449 Materials testing machines 11Hardness testing• Hardness acc. to Vickers DIN EN ISO 6507, ASTM E92 Hardness testing machines 31• Hardness acc. to Brinell DIN EN ISO 6506, ASTM E10 Hardness testing machines 31• Hardness acc. to Rockwell DIN EN ISO 6508, ASTM E18 Hardness testing machines 31• Hardness acc. to Knoop ISO 4545, ASTM 384 Hardness testing machines 31• Martens hardness EN ISO 14577 Hardness testing machines 31• Hardness at weld joints EN 1043 Hardness testing machines 31• Hardness testing for aeronaut. aoolications DIN EN 2002-7 Hardness testing machines 31

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Contents Test standard Test means/Test device PageFatique test• Tensile creep test DIN 50118 Creep testing machine 29• Rotating bending test DIN 50113 Rotary bending testing machine 26• Fatique test (Wöhler test) DIN 50100 Servo-hydraulic testing machine 26• Standard Practice for Strain-Controlled ASTM E606-92 High-frequency testing machine 26

Fatique Testing • Steel wires for the reinforcement of concrete DIN 696 High-frequency testing machine 26Impact and high-speed test• Determining the Charpy impact resistence DIN EN ISO 179 Pendelum impact tester 28• Determining the Charpy impact resistence, DIN EN ISO 1455 Pendelum impact tester 28

instrumented impact test• Standard Test Method for Notched Bar, ASTM E23 Pendelum impact tester 28

Impact Testing of Metallic Materials• Methods for Notched Bar Tests, Part 2. BS 131: Part 2 Pendelum impact tester 28• The Charpy V-Notch, Impact Test on Metals• High-speed tensile test and DIN EN ISO 6603-2 High-speed testing machine 28

impact penetration testDeep drawing test• Cupping test on sheet matal and strips DIN EN ISO 20482 Ductility testing machine 30

(Erichsen-cupping)• Cupping test on sheet matal and strips ASTM E643-84 Ductility testing machine 30

(Olsen-cupping)• Fukui test – Cupping deep drawing DIN 50155 Ductility testing machine 30

test for determining earing

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Application test-curve in testXpert® Example of mounting

Tensile test

Standard: EN 10001-1, ISO 10275ISO 10113

Type of test: Tensile test with determ.of r- and n-value

Material: steel sheetExtensometer: Macro with reduction

in width monitorGrips: Wedge-screwtestXpert®: B069008

Standard: EN 10138Type of test: Tensile testMaterial: StrandGrips: HydraulictestXpert®: B069008

Standard: DIN 488, EN 10080Type of test: Tensile testMaterial: Steel wire for the

reinforcem. of concreteExtensometer: MacroGrips: HydraulictestXpert®: B069008

Standard: EN 10002-5Type of test: tensile testMaterial: steelExtensometer: HT-ExtensometerGrips: ThreadtestXpert®: BX069008.00xx-08

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Application test-curve in testXpert® Example of mounting

Fatique test

Standard: DIN 488Type of test: Alternating tensile testMaterial: Steel wire for

reinforcem. of concreteGrips: Special grips for

steel wirestest frequency: 80 HztestXpert®: RAB06942000

High-speed test

Type of test: High-speedtensile test

Material: AluminiumGrips: Special grips for

flat specimenTest speed: max. 20 m/stestXpert®: RAB0694100

Instrumented indentation testfor hardness

Standard: EN ISO 14577Type: Martens HardnessSpecimen: ComponentTesting machine: Z2.5/TS1SHardnessmeasur. head: 2.5 KNtestXpert®: B06914.X0.X0

Standard: EN ISO 6508Type: Hardness acc.

to Rockwell ASpecimen: Reference blockTesting machine: Z2.5/TS1SHardnessmeasur. head: 2.5 kNtestXpert®: B069014.X0.X0

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Cutting force P in kN

if P ≥ 650 kN, than

Ls = Circumference of spec. in mm σB = Tensile strength in kPa a = Thickness in mm

Specimen preparation

Specimen blanking pressesfor the economical manufacture oftensile specimen from sheet steel.Due to the low cutting speed andthe shape of the punching tool,the work-hardening og the cutedge amounts to max. 10 % ofthe specimen thickness. The sligthpunch oversize – and thus thework-hardening – is removed withthe specimen grinder.

Specimen grinding machineZwick 7120for grinding punches specimensto shape and size. Exact grindingdimensions of the parallel specimenlength through heigth-adjusted ofthe whole grinding unit (max. powerconsumtion 0.75 kVA).

Typical round specimens (Figure „specimen types“, b)

Standard Dimensions, mmd L0 D Lc L

DIN EN 10002 (Annex C) ≤4 100/200 L0 + 50DIN 50125, Form A 10 50 12 ≥60 ≥140

12 60 15 ≥72 ≥16016 80 20 ≥96 ≥205

ASTM E8 12.5 50 608.75 35 45

JIS Z 2201 No 4 14 50 60

Typical flat specimens (Figure „specimen types“, a)

Standard Dimensions, mma b L0 B Lc L ∆b

DIN EN 10002, type1 12,5 50 75 165 0.003DIN EN 10002, type 2 20 80 30 120 ≥250 0.052DIN 50 114 ≤3 20 80 30 120 ≥250DIN 50 125 3 8 30 12 38 ≥115

5 16 50 22 65 ≥1756 20 60 27 80 ≥2108 25 80 33 105 ≥260

JIS Z 2201 (13A) 20 80 30 120JIS Z 2201 (13B) 12.5 50 20 60JIS Z 2201/ 5) 25 50 30 60JIS Z 2201/1B) 25 200 30 220JIS Z 2201/1A) 40 200 220ASTM E8 12.5 50 20 60 ≥200 0.05

40 200 50 225 ≥450 0.1

Specimen blanking presses

Series/Type RZ50 RZ65 RZ100 RZ150Structural shape C - frame O-frame O-frame O-frameCutting force, kN 500 650 1,000 1,500Specim. throughput, 1/min 6 6 6 6Specim.thickness, mm 0.2 - 6 0.2 - 6 0.2 - 6 0.2 - 8Max. power cons., kVA 4 4 4 10

Specimen grinding machine

Specimen types

Specimen blanking press

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Materials TestingMachines

Field of application

Materials testing machines arepredominantly used for thedetermination of the strength anddeformation behaviour of specimensand components. For this purpose,tensile, compression, bending orshear tests and with special deviceseven torsion tests are carried out.Large test areas, test travels,speed and measuring ranges,exchangeable test tools and testdata transducers enable tests to becarried out both on small specimensand on compact components,subassemblies and structures.Tailor-made to applications, materialstesting machines enable the user toexamine the characteristic featureprofile of all kinds of materials andmaterial combinations. The spectrumof application and the performanceand efficiency of the testingmachines are decisively determinedby the flexibility of the test software.

Basic concept

The Zwick program includesuniversal testing machines astabletop and floor standing designswith different measurement andcontrol systems, load frames,drives and versatile function andsupplemen-tary units.

However in order to be able tooffer the best machine for eachrequirement, Zwick has developeda user-related concept. The usercan choose among three machineversions, each of them beingcompletely different as to equipment,performance features and also asto the capability of expansion:

• BasicLine• Standard Line• Allround Line

The decisive testing machinecomponent is the measurementand control system. Its conceptionand its scope of performance decidewhich drive can be controlled, whichmeasurement system can beconnected to it and which functionscan be controlled with it – and theythus determine the range of appli-cation and the testing machine’scapability for future expansion.

The advantages to the user ofthe three different testing machineversions are as follows:

• The BasicLine is particularlysuitable for functional tests oncomponent parts and for thesimple materials test.

• The Standard line is ideal to solvesimple test jobs reliably. It is alow-cost, sturdy solution whichcovers many testing needs.

• The Allround line is the basis for alarge spectrum of demanding testjobs and can easily be expandedwith the requirements becomingmore demanding. It is thus asolution that can be relied on forfuture requirements.

Measurement and controlsystem BasicLine

The electronics taken from existingZwick machine types guarantees avery high availability and reliability ofthe test system. The measurementand control electronics is compactlypacked in a housing. BasicLinetesting machines can be operatedin the Stand Alone mode withouta PC and they can be operateddirectly via function keys on thetesting machine. As standard it isadditionally possible to operate theBasicLine with the test softwaretestXpert®, thus profiting from allthe advantages of standardized testprograms and from the many yearsof experience on the developmentsector.

Measurement and controlsystem testControl(for standard and allround version)

By using most recent technologiesand by granting highest qualitystandards testControl offers amaximum of technical performanceand a long-term investmentguarantee. These are the particularfeatures of testControl:

• Time-synchronous test dataacquisition with high resolutionand measuring frequency

• Real-time processing of the testdata in a 500 Hz cycle for themonitoring and event-relatedtest sequence control (e.g. speedchange when reaching the yieldor proof stress) and for safety limitvalues

• Adaptive control for exactlyreproducible speeds and positions

• The measurement and controlelectronics and the powerelectronics for the drive systemin question are integrated in ahousing in a space-saving way.Thus, the usual cabling can bedispensed with.

Materials testing machine BasicLine Z020

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The measurement and controlsystem testControl is availablein 2 variants:

Stand Alone Variant

Easy and reliable operation viacoloured display, 10-key keyboardand a few function keys – withoutPC. A printer may be connecteddirectly for the printout of testresults.

PC-Variant

The system may be configuredand expanded to cope with themost different applications. PCand user software testXpert® makeapplications very comfortable andextremely flexible.

Load frames

Different load frame versions fortest loads up to 2.000 kN areavailable as standard. For specialapplications special versions canbe developed and manufactured,e.g. load frames in horizontalposition suitable for the testingof long steel ropes.

Single-column load frame fortable-top testing machines(zwicki)

These load frames are designedwith very rigid aluminium high-precision extruded profiles. Theworking area is freely accessiblefrom 3 sides. Thus, it is ideal forthe various tests on small partsand for Zwick hardness testingmachines. It only requires a smallfloor space. Due to its light weight,it is easy to transport.

Two-column load frames fortable-top testing machines

The load frames of the BasicLineare designed with 2 round steelcolumns. The load frames of theStandard and Allround Line aredesigned with patented aluminiumhigh-precision extruded profiles.They are light, very rigid and servesimultaneously as lead-screw guideand protection. T-shaped grooveson the outer sides allow a simplefitting of accessories as e.g. safetydevices without being impeded bythe crosshead.

All load frames with two profiles –except for the BasicLine – can beequipped with legs. Advantagesare:

• Positioning of the working areato an optimum height for the user

• Comfortable seated operationwith absolute freedom for legmovement (also suitable forwheelchair users)

Load frame asfloor standing model

In load frames for test loads up to150 kN patented aluminium high-precision extruded profiles and 2or 4 hard-chrome plated round steelcolumns are used as supportingand guide column. For testingmachines with a hybrid drive systemthe stationary piston rods are at thesame time used as supporting andguide columns. All load frames withan electro-mechanical drive systemmay optionally be equipped with asecond working area allowing e.g.a rapid change of the test modewithout having to change theequipment.

Materials testing machine Z2.5 (zwicki)with testControl Stand Alone variant

Materials testing machine Z050 with legsand testControl PC variant

Materials testing machine Z100with testControl PC variant

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Features of the BasicLine, Standard- and Allround Line

Machine component or funktion BasicLine Standard Line Allround LineLoad frame• Type of set-up

* Table-top machine (nominal force) 500 N to 20 kN 1 kN to 150 kN 1 kN to 150 kN* Floor stand. machine (nominal force) - 50 to 2,000 kN 50 kN to 2,000 kN

• Support and guiding columns* No. of columns 2 2 or 4 2 or 4* No. of Aluminium profiles 1 (Z0,5) 1 or 2 1 or 2

• No. of working areas 1 1 or 2 1 or 2• Expanded design (higher and/or larger) - ✓ ✓

Drive system• Elektro-mechanical

* No. of ball screws 1 or 2 1 or 2 1 or 2* DC-Motor ✓ only zwicki only zwicki* AC-Motor - up to 600 kN1) up to 600 kN1)

• Servo hydraulic - from 400 kN2) from 400 kN• Hybrid - - from 400 kNMeasurement and control system• BasicLine (also usable without PC) ✓ - -• testControl PC-variant (Standard) - ✓ ✓

testControl Stand Alone variant (Option) - optional optionalSoftware• test software testXpert® (with PC) optional optional optionalTransducer• Strain gauge load cell 1 (interchangeable) 1 (optional up to 2) 1 (optional up to 3)• Digital crosshead monitor integrated integrated integrated• Digital extensometer - optional 1 yes (optional up to 3)• Analogue extensometer - optional 1 yes (optional up to 3)Connection ofexternal systems• Digital extensometer - ✓ ✓

• Analogue extensometer - ✓ ✓

• Analogue reduction-in-width monitor - ✓ ✓

• Video Capturing - ✓ ✓

• Switch Contact - ✓ ✓

• Switch Control - ✓ ✓

• Further measurement systems - ✓ ✓

Control of external systems• Specimen grips(mot., pneum., hydr.) - - ✓

• Extensometer systems - semi-automatic full-automaticSupplementary unitsfor special applications(optional)• Torsion drive - - ✓

• Torque transducer - - ✓

• Multi-channel force measuring system - - ✓

• High-temperature testing equipment - (✓) ✓

• Low-temperature testing equipment - (✓) ✓

1) Without zwicki2) Only SP-matarials testing machine

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Materials testing machine Z400E

Load frames and drive systems of the BasicLine

Series Z0.5 Z005 Z010 Z020• Type table top table top table top table top• Max. load, kN 0.5 5 10 20• Working area, max.

* Height, mm 596 561/1,061 1,041 1,041* Width, mm no limit 420 420 420* Depth, mm 99.5 no limit no limit no limit

• Max. crosshead speed, mm/min 1,500 500 1,000 500• Crosshead travel resolution, µm 0.226 0.05 0.09 0.045• Max. power consumption, kVA 0.4 0.6 0.6 0.6 Materials testing machine Z1200H

Drives

Electro-mechanicaldrive systems

The basis of all electro-mechanicaldrive systems are backlash-free andlow-friction ball screws and digitallycontrolled drive systems. They areused with load frames for test loadsof up to 600 kN. Together with thedigital measurement and controlsystem they have the followingadvantages:

• Extremely high, stepless speedrange

• Very low speeds adjustable(from about 0.5 µm/min on)

• High-precision and exactlyreproducible positions andspeeds

The testing machines designedwith single-column load frames(zwicki and BasicLine) are equippedwith low-cost d.c. drives, all theothers with particularly low-inertia,brushless three-phase drives.

Hydraulic drive systems

This drive unit is located centrallyon the upper fixed crosshead. Thus,the test area lying beneath is easilyaccessible. A servo or proportionalvalve regulates the oil flow betweenthe hydraulic unit and the differentialcylinder. The oil cushion in the

upper pressure area avoids the”piston jump“ the rams are knownfor after the specimen break.The resolution of the piston traveltransducer is 1.25 µm (less than1/400,000 of the max. test travel).The hydraulic drive unit is the mosteconomic solution particularly forlarge test loads.

Hybrid drive systems

In this patented drive unit, theadvantages of the electro-mechanical drive (high precision)are combined with those of thehydraulic drive (high force density).The result is that even cylinders withhigh forces and long travels canbe driven and positioned with anutmost accuracy. According to thisprinciple 2 parallel synchronouscylinders coupled with the movingcrosshead can regardless of theload applied be displaced exactlysynchronously by following preciselyand practically instantaneously thepreselected position of an electronicpilot drive unit. The special featuresof this drive are the following:

• Large test stroke (no adjustmentof the fixed crosshead required).

• Comparatively low height of theload frame.

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Load frames and drive systems for high forces (standard types with hydraulic or hybrid drive)

Series Z400H Z600H Z1200H Z2000H Z600Y Z1200Y Z2000Y• Max. load, kN 400 600 1,200 2,000 600 1,200 2,000• Dimensions of load frame

* Heigth, mm 2,900 3,000 3,500 4,200 2,750 3,147 4,200* Width, mm 1,020 1,080 1,300 1,400 1,530 1,614 1,870* Depth, mm 480 500 880 905 788 790 1,100

• Working area* max. height, mm 500 500 600 600 1,895 2,300 2,400* with adjustable crosshead, mm 900 900 1,000 1,000* Width, mm 670 670 850 870 790 860 950* Max. travel , mm 500 500 600 600 850 1,000 1,000

• Travel resolution, µm 1.25 1.25 1.25 1.25 0.05 0.05 0.05• Max. test speed, mm/min 200 200 200 200 250 250 250• No. of columns 2 2 4 4 2 2 2• Max. power consum., kVA 8.5 8.5 15 23 8.5 15 23

Load frames and drive systems of the Standard and Allround Line (with electro-mechanical drive system)

Series Z1.0 Z2.5 Z005 Z010 Z020 Z030 Z050• Type table top table top table top table top table top table top table top• Max. load, kN 1 2.5 5 10 20 30 50• Working area

* Height,short, mm - 573 - - - - -normal, mm - 1,073 1,058 1,058 1,058 - -higher, mm 1,373 1,373 1,458 1,458 1,458 1,380 1,380higher + larger, mm - - - 1,787 1,787 - -

* Width, normal, mm no limit unbegr. 440 440 440 440 440larger, mm - - - 640 640 - -

* Depth, mm 99.5 99.5 no limit no limit no limit no limit no limit• Crosshead speed

* max., mm/min 1,800 800 3,000 2,000 1,000/2,0001) 1,000 600• Crossh. trav. resolution, µm 0.0002 0.0001 0.041 0.027 0.014/0.054 0.027 0.016• Max. power consum., kVA 0.4 0.4 2/1.9 1.9 2.1/2.6 2.3 2.3

Series Z050 Z100 Z100 Z150 Z250 Z400 Z600• Type floor stand. table top floor stand. floor stand. floor stand. floor stand. floor stand.• Max. load, kN 50 100 100 150 250 400 600• Working area

* Height,short, mm - - - - - - -normal, mm 1,824 - 1,824 1,715 1,715 1,800 1,940higher, mm - - - - - - -higher + larger, mm 1,765 1,360 1,765 1,660 1,660 - -

* Width, normal, mm 630 640 630 630 630 630 740larger, mm 1,030 - 1,030 1,030 1,030 - -

* Depth, mm no limit no limit no limit no limit no limit no limit no limit• Crosshead speed

* max., mm/min 400/2,0001) 200/1,5001) 200/1,0001) 900 600 250 200• Crossh. trav. resolution, µm 0.027 0.026 0.0136 0.0123 0.0082 0.031 0.025• Max. power consum., kVA 5 6 5 5,5 6 7/132) 20/262)

1) depending on the selected drive system and its power 2) with hydraulic grips

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SP-testing machines with hydraulic drive system

Series SP400.xx SP600.xx SP1000.xx SP1200.xx SP1500.xx SP2000.xx• Max. load, kN 400 600 1,000 1,200 1,500 2,000• Working area

* Height, mm (.00)1) 100-600 100-600 120-720 120-720 120-720 120-720* Height, mm (.01)2) 0-800 0-800 0-900 0-1,000 0-1,000 0-1,000* Width, mm 670 670 700 850 850 850

• Max. travel, mm 500 500 600 600 600 600• Travel resolution, µm 5 5 5 5 5 5• Max. test speed, mm/min 250 200 200 200 200 200• No. of columns 2 2 4 4 4 4• Max. power consumption, kVA 10 10 18 18 18 30

1) with fixed crosshead 2) with adjustable croshead

Compression testing devices for SP testing machines

Series/type X070220 X070220 X070220 X070220 X070220 X070220-194 -210 -226 -240 -254 -268

• Max. load, kN 400 600 1,000 1,200 1,500 2,000• Diameter, mm 230 230 300 300 300 300

Bending testing devices for SP testing machinesExample: support radius 25 mm, support separation 30 to 600 mm, support height 100 mm, flexure fin height 200 mm

Baureihe/Typ X070220 X070220 X070220 X070220 X070220 X070220-196 -212 -228 -242 -256 -270

• Max. load, kN 400 600 1,000 1,200 1,500 2,000• Bending stamp-Ø, mm1) 30,40,50 30,40,50 50 50 50 50

1) Separate order items

Special Metals Testing Machine SP

Special MetalsTesting Machine SP

This testing machine was speciallydesigned for the testing of flat,round and profile specimens madeof steel. In addition to tensile tests,it is also possible to carry out com-pression, bending and folding tests.It has a particularly rigid load framewith a hydraulic central drive on theupper optionally fixed or adjustablecrosshead. It is equipped withhydraulically-operated wedge gripsas standard. For the test loadmeasurement, electrical load cellsare used. The grip separation ismeasured contact free with a

displacement transducer with aresolution of 0.5 µm. In spite ofits size the SP machine does notneed a special foundation. It isplaced on rubber mats directlyonto the concrete floor.

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testXpert-Screenshot: Tensile test on sheet steel with r- and n value determination

Test software testXpert®

Range of application

testXpert® is the universal Zwicktest software for materials,component, and functional testing.It’s application range goes fromZwick materials testing machines(for tensile, compression, flexureand functional testing) to hardnesstesters, pendulum impact testers,extrusion plastometers, automatedtest systems, etc. right up to therefurbishment of testing machinesof a variety of makes and models.

Duties and functions

The essential fields of use oftestXpert® are:

• verification and re-equippingof the test machine

• preparation of the test or testseries

• performance of the test• evaluation and documentation• data management• quality management and• data exchange between

testXpert® and other applications(Word, Excel etc.)

testXpert® supports the user forall tasks with software wizards andeditors, explanatory pictures andvideo sequences, situation-specificuser tips, warnings, error messagesand online help.

Future-oriented concept

The testXpert® test software usesthe special properties of the object-oriented programming with respectto a clear grouping in tasks andfunctions. Structure and contentsare determined by the Zwickapplication and software know-how. The testXpert ® concept istherefore a guarantee for highest

flexibility, functional safety as well assimple usability.

The essential characteristic featuresare:

• uniform basic software for allapplications

• modular system for test programs• user support through software

tools

Modular system

The test programs are compiledby Zwick from a selection of severalhundred software modules. Themodules are sub-divided intoclasses such as test parameters,test sequence phases, screen viewsetc. They are continuously updatedand expanded with respect to newstates of knowledge and necessarysupplements. This makes testXpert®

an intelligent software, and thusenables the realization of testprograms strictly to test standardsand test programs related topractical applications. Thanks tothe numerous possibilities of thissystem, testXpert® can be put

to universal use for a wideapplicational spectrum and fora variety of testing machines.

Test programs

The test programs compiled byZwick stipulate how tests are tobe run. Their basis are selectedsoftware modules that are linked toone another and are pre-configuredthrough fixed parameters dependingupon the functions required. Thusthe user receives from Zwick a”test template“ in which only variableparameters must be entered.

There are three variants available fora wide range of requirements:

• Master test programs• Standard test programs, and• Customized test programs

International qualitystandards

To comply with international qualitystandards, each and every versionmust be transparent, documentedand archived for 10 years.

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The testXpert® test software fullymeets these requirements and eventhe particularly strict guidelines ofthe Good Manufacturing Practices(GMP).

The entire software developmentprocess and its components arediligently documented and archivedfrom the source code through tothe software tools used, for eachand every version. This is validfor each phase from the analysisvia the specification, design andimplementation up to the test.Conformity to the standardISO 9000-3 for developmentof testXpert® has been confirmedvia audit report no. QM-F-96/1016.

Safety in detail

Windows software is normallyused in offices. However, testXpert®

takes over an additional andespecially critical task: monitoringand controlling machines. Machinedamage and potential danger topersons must be ruled out. That’swhy testXpert® doesn’t use anyoverlapping windows in the testmode to avoid hiding importantdisplays or key fields.

Automatic acceptanceof system data

Different test jobs require differenttest machines with differentand usually, interchangeablecomponents. Their specificproperties are characterised bythe system data (nominal force,travel, speed range, mountingheight, calibration factors, etc.).Organisational data also belongto the above, e.g. the seriesnumber or the date of the lastcalibration.

testXpert® accepts this dataautomatically directly followingthe program start

• for the necessary settings• for the determination of safety

limit values• for the correct measurement

signal evaluation

Furthermore testXpert® checkswhether or not

• the test can be carried outwith this configuration

• all settings have been made• the data have changed for the

current test

Simplest operation

Operation is reduced to a one-button operation, i.e. activatingthe start button, for standardapplications. This is possiblebecause testXpert® automaticallyrecords the test data, anddependent upon this, controlsand monitors the test sequenceand determines and documentsthe test results.

Preparation of a test series requiresonly two steps:

• call-up the test program foreseenfor the required application

• input or selection of variableparameters

Optimum user information

All displays necessary for carryingout a test and a test series, canbe grouped together in a clearand concise manner in one singlescreen setting.

• input fields for specimen-specifictest parameters

• curve diagram (single or multiplecurves)

• tables for test results• tables for result statistics

Data saving for further use

Depending upon the preselectionin the test program, not only alldata but also selected result datafrom a test or test series canbe saved. Saving of all dataoffers the possibility of tracingthe origin of the result data upto configuration and settings forthe test machine. The standardizedmeasurement data, i.e. the dataconverted to its basic units canbe repeatedly displayed in thesimulation mode and can alsobe evaluated according to othercriteria.

Video Capturing

The test software testXpert® notonly supports the user by meansof ”Help“ videos. It is also possibleto carry out multimedia tests byusing a video camera and a video-capture card with the video picturesbeing recorded time-synchronouslywith the test data.

• With the cursor keys, a ”videoreticle“ can be moved over thetest curve and the correspondingpicture can be displayed

• The pictures can be capturedat a preselected distance ofthe measuring points or independence on the event

• The video can also be playedalone, irrespective of testingmachine

• Distances between two pointsand angles between three points,radii, diameters and areas canbe measured from the specimenin pictorial representation

• Optionally, the pictures can alsobe output with dimension linesand test data

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Force transducer(load cells)

Strain gauge load cells are availablefor nominal load capacities from5 N up to 2000 kN. Together withthe digital measurement electronicsthey have the following advantages:

• Automatic recognition of all loadcell settings, calibrationparameters e.c..Therfore thechange of load cells is very easy

• Automatic zero and sensitivityalignment

• Compensation of temperaturefluctuations

• High measuring frequency• High test data resolution• Accuracy of 1% of the displayed

value (1 % error limit) from 0.2 to120 % of the nominal load (1 % to100 % for load cells with nominalload £ 500 N) and 0.5% of thedisplayed value (0.5 % error limit)from 1 to 100 % of the nominalload

• Overload protection• Manufacturer’s test certificate to

give proof of the works calibration

Load cells with one or two sidedmounting studs and self-identifyingsensor plugs are available fornominal load capacities from10 N on.

Specimen gripsfor tensile tests

Zwick offers a large spectrum ofspecimen grips in different versionsand test load levels to cover thelarge range of application of metaltesting. The following grips areavailable:

• Wedge grips• Wedge screw grips• Pneumatic grips• Hydraulic grips

Wedge grips

• Simple design, self-gripping• Adaptable to different specimen

dimensions by using differentjaw faces

• For large forces with pneumaticactuation

Wedge screw grips

• Adjustable initial clamping force• Large clamping range suitable for

different specimen dimensions

Pneumatic andhydraulic grips

• Increased user comfort forhigh specimen throughputs

• For tensile, compression andalternating load and safe holdingof the specimen also afterspecimen break

• Large clamping area withouthaving to change the jaws

• Integrated system connection bymeans of a T-slot change system

• Force control when closing thegrips and the jaws

• Optionally available withautomatic clamping forceadjustment and gentle closingforce control

Force transducer with sensor plug Wedge grips 8405 (50 kN) Wedge screw grips 8506 (100 kN)

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Pneumatic grips 8597 (100 kN)

Wedge screw grips for testing forces from 0,5 to 250 kN

Series/type 8106 8206 8306 8406 8406 8506 8506 8507• Max. testing force, kN 0.5 2.5 10 30 50 100 150 250• Max. spec. thickn., mm 5 10 30 30 30 30 30 64• Max. spec. diam., mm 30 30 30 30 30 30 30 80• Max. Clamping surface

* Width, mm 15 30 60 60 60 60 60 80* Height, mm 30 60 60/80 60/80 80 80 80 100/120

• Operation manual manual manual manual manual/ manual/ manual/ manual/(opening/closing) motorized motorized motorized motorized

• Construction height, mm 64 110 125 137 146/147 176/177 176/177 252• Individual weight, kg 0.2 3 15 16 37/50 44/50 42/46 112

Pneumatic grips for testing forces from 1 to 30 kN(single side closing)

Series/type 8197 8297 8397 8497 83881)

• Max. testing force, kN 1 2.5 5/10 30 5• Clamp. force at 6 bar, kN 1.7 3. 6 9/18 35 5/13• Max. opening, mm 20 20 24 24 5• Max. camping surface

* Width, mm 60 60 60 60 60* Height, mm 30/50 30/50 50 50 80

• Construction height, mm 95 95 162 175 182• Individual weight, kg 1.7 2.4 8.2/10 15 6.6/7.5

1) with load reduction curve

Pneumatic grips for testing forces from 10 to 100 kN(double side closing)

Series/type 8397 8497.03 8497.50 8597• Max. testing force, kN 10 20 50 100• Clamp. force at 6 bar, kN 27 27 60 120• Max. opening, mm 25 25 50 30• Max. camping surface

* Width, mm 60 60 110 74* Height, mm 50 50 110 74

• Construction height, mm 208 225 306 341• Individual weight, kg 14 14 15/53 53

Wedge grips for max. testing forces from 2,5 to 600 kN

Series/type 8201 8302 8303 8402 8403 8502 85098509850985098509 85208520852085208520• Max. testing force, kN 2.5 10 10 50 50 100 250 600• Max. spec. thickn., mm 10 20 4,5 18 10 6 - 30 16 - 48 16 -48• Max. spec. diam., mm - 12-20 - 10 - 18 - 10 - 30 16 - 52 18 - 62• Max. Clamping surface *Width, mm 32 60 30 60 30 60 80 100*Height, mm 40 50 45 40 77 48 85 100

• Operation (open./clos.) manual manual manual manual manual manual man./pneum. pneum.• Construction height, mm 145 165/175 110 165 196 210 320 400• Individual weight, kg 1.9 6.5 3 13.5 5 27 70/100 300

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Hydraulic grips 8594 (250 kN)Hydraulic grips with dual clamping system(for strands e.c.)

Hydraulic grips for testing forces from 50 to 2,000 kN

Series/type 8801 8494 8802 8592 8803 8594• Max. testing force, kN 50 50 100 100 250 250• Max. clamping force, kN 100 100 255 250 410 410• Max. hydr. pressure, bar 300 300 300 300 300 480• Max. spec. thickn., mm 40/59 59 59 59 59 59• Max. spec. diam., mm Ø15 Ø15 15/59 15/59 15/59 15/59• Clamp. surface, width, mm 80/Ø50 Ø50 Ø74 Ø74 Ø74 Ø74

height, mm 70 - - - -• Type of clamping single-sided double-sided single-sided double-sided single-sided double-sided• Construction height, mm 205 205 303 303 303 303• Individual weight, kg 37 37 70 70 70 70

Series/type 8595.03 8595.02 8597.01 8597.02 8598.00 8599.00• Max. testing force, kN 400 400 600 600 1,200 2,000• Max. clamping force, kN 590 590 950 950 1,500 3,000• Max. hydr. pressure, bar 480 480 480 480 480 480• Max. spec. thickn., mm 80 80 100 100 60 100• Max. spec. diam., mm 65 65 100 100 60 100• Clamp. surface, width, mm 65 65 60 60 Ø150 Ø220

height, mm 40 40 80 80 - -• Min. gauge length, mm 170 170 220 220 350 500• Type of clamping single-sided double-sided single-sided single-sided double-sided double-sided• Construction height, mm 260 260 270 270 470 303• Individual weight, kg 130 150 300 330 680 900

Hydraulic grips withdual clamping system

These specimen grips have beendeveloped particularly for the tensiletest on high-strength prestressingstrands and concrete steel. Thetensile force is transmitted from thespecimen onto the specimen gripsover 2 clamping systems arrangedin tandem. So the clamping force isdistributed over a longer specimensection and the tensile force isreduced in the specimen grips intwo steps. The frequent specimenbreaks within the gripping rangecan thus be avoided.

Another advantage: The retrofittingof the specimen grips from concretesteel to prestressing strands or viceversa becomes easier and can berealized within a short time.

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Analogue extensometer(for manual operating)

Series/type TC-EXACLEL TC-EXACLEL TC-EXACLEL.001 .002/.003/.004 .005

• Gauge length, mm 25/50 20/10 20/10• Spec. thickn./diam., mm 28 25 40• Measurem. travel, mm 25 +2/-1 ± 2• Travel transducer inductiv strain gauge strain gauge Bending testing device with sliding system

Test toolsfor compressionand bend tests

For the performance ofcompression and bend tests amultitude of test tools of differentversions and dimensions as wellas for different test load rangesare available.

The bending supports and diesfor the different bending and foldingtests are usually exchangeable. Theadjustability of the support distanceand the free height of the bendingsupports and dies allow 90° bendtests and bending-folding tests withangles of up to 180°.

Deformation transducers

Extensometers

For the extension measurement,measurement systems with differentgauge lengths, test travels andresolutions are available:

• Extensometers with contactmeasurement for the manualattachment to the specimen

• Extensometers with contactmeasurement for the manualor automatic attachment ofthe feelers to the specimen

• Extensometers with non-contact,optical measurement withspecimen marks attached onthe specimen

The manually attachable,incremental measurement systemscan already be used with the testingmachines of the standard line.

Motor-driven measurement systemsare controlled automatically or bymeans of a manual control unit. Themacro extensometer is particularlysuitable for the determination of theproof stress as well as for theuniform elongation and for the strain

at break. For the determination ofthe Young’s modulus of elasticitya small test travel and a highresolution should be selected.The long-stroke and the non-contact extensometers, due totheir low resolution, are only usedfor larger gauge lengths.

Reduction in width monitor

For the measurement of thechange in width, particularly forthe determination of the verticalanisotropy r (r-value) an extensionmodule for the macro extensometeris used. With this module thechange in width is measured witha high precision in 2 or 4 resp. in1 or 4 cross-section levels.

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Incremental extensometers

Series/type TC-EXMACRO TC-EXLONGS• Describtion Macro Long stroke• Gauge length, mm 10 bis 100/205 10 bis 1,000• Gauge length adjustment manual or automatic manual• Method of attachment manual or automatic automatic• Measurem. travel, mm 80/120/160/75/112,5/150 1,000 – L0

• Resolution, µm 0.12/0.18/0.24/0.3/0.45/0.6 5

Incremental reduction in width monitor

Series/type TC-EXMACWD TC-EXMACWD• Application with Macro and long stroke Macro and long stroke• Specimen width, mm 10 to 15/20 to 25 (2 steps) 10 to 25 (1 step)• No. of measurem. levels 2/4 1/4• Gauge length adjustment manual manual• Method of attachment manual or automatic manual or automatic• Measurem. travel, mm 5 >6• Resolution, µm 0.02/0.1 0.02/0.1

Incremental clip-on extensometer(for manual operation)

Series/type TC-EXICLEL.001 TC-EXICLEL.002• Description Incremental Incremental

clip-on extensometer clip-on extensometer• Gauge length, mm 20/25/30 50/55/65/70

(optional 50/80) (optional 80/85/100/105)• Spec. thickn./diam., mm 20x30 or Ø 20 20x30 or Ø 20• Measurem. travel, mm +13.5/-0.2 +40/-0.2• Resolution, µm 0.1 0.1

Series/type TC-EXICLWD TC-EXICLBI TC-EXACLWD.001 .001 .001

• Description Incremental Biaxial Strain gaugereduction in incremental reduction inwidth monitor clip-on extens. width monitor

• Spec. thickness, mm 10 to 20 10 to 20 10/12.5/20/25• No. of measurem. levels 1 1 2• Measurem. travel, mm 1.5 to 11.5 1.5 to 11.5 4• Resolution, µm 0.1 0.1 0.04

Non-contacting extensometers

Series/type TC-EXOPTIC TC-EXLASER TC-EXVIDEO• Description Optical Laser- Video

extensometer. extensometer. extensometer• Gauge length (L0), mm 10 to 900 10 bis 500 5 bis 1,000• Measurem. travel, mm 900 minus L0 max. 1,000 % to L0 = 20 mm 50/100/200/500/1,000,

dep. on resolution• Resolution, µm 5 12 0.5/1/2/5/10• Travel transducer Incremental Laserscanner Video, analogue

Macro with reduction in width monitor

Incremental clip-on extensometer

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Polar systemX-Linear systemClip-on system

Specimen handlingsystems

Application

Automatic specimen handlingsystems are used for the efficienttesting of large series withspecimens of the same type.

Specimen handling systems can besupplied in 4 task-specific designs:

• Clip-on system• X-linear system• Light portal system• Portal system

Common features:

• Integrated system designedto conform to CE regulations(like the Testing Machines)

• Data exchange with each Zwickuniversal testing machine viaserial interface

• Use with conventional PC’s

Advantages to the user

• Automatic operation• High reproducibility of the test

conditions and of the test results• High integrity of data and

statistical long-term monitoring• Manually controlled tests also

possible• Simply adapted and expanded to

specific requirements, throughmodular system

Construction and functionof the individual systems

The clip-on system

is used for tensile tests. It consistsof a movable unit with two chains,arranged over one another, andrunning in an oval, with spring clipsor magnets for horizontal holdingof the specimens.

Various holding devices for differentspecimens can also be used incombination. Depending on thedesign of the holding device andthe nature of the specimen, thebroken specimen can also bebrought back to the storage place.

The X-linear system

enables tensile, bending andcompression tests to be performed.It consists of a movablesubstructure with the electronicunits, a linear handling axis, a pincergripper and – optionally – a movablemagazine table. The whole systemis controlled by a stored programcontroller. The cross section canbe measured automatically at upto three places.

The light portal system

is used for tensile, hardness,roughness or bending tests. It isconsiderably larger, and throughits robust design it is suitable alsofor rugged environments. Thesystem consists of 3 axis and arotating gripper unit. It is controlledvia a stored program controller.An integral crash sensor stops thewhole plant in an emergency, e.g.in the case of contact with people.

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Specimen handling systems

Characteristic, feature Clip on X-Linear Polar Light portal Portalsystem system system system system

No. of storage places 50 – 100 60 – 120 100 – 400 200 – 400 140 – 240(Standard)Specimen types/ round and inherently rigid round and round and round andfeatures flat specimen, round and flat flat specimen flat specimen flat specimen

wires, foils specimen from weight weight weightappr. 0.2 mm thick to 20 kg to 1 kg to 10 kg

Specimen dimensions• Shoulder or strip width up to 50 mm up to 35 mm up to 70 mm up to 40 mm up to 70 mm• Shoulder or wire diameter up to 16 mm up to 22 mm up to 60 mm up to 18 mm up to 40 mm• Thickness (standard) up to 5 mm up to 6/12 mm up to 60 mm up to 10 mm up to 60 mm• Total length up to 350 mm up to 260 mm up to 500 mm up to 260 mm up to 500 mm

(variabel)1)2) (variabel 2) via (variabel via (variabel via (variabel viamagazine inserts) magazine inserts) magazine inserts) mag. limit stops)

Cross section measurement• Thickness or diameter thickn. o. inq.. ✓ ✓ ✓ ✓

• Width - ✓ ✓ ✓ with centering5)

• No. of measur. levels/spec. 1 1/3 1/3 1/3 1/3Specimen disposal back to the back to the to various to various to various

storage place3) storage place4) bins4) bins4) bins4)

(hardness testing)Specimen identification ✓ ✓ ✓ ✓ ✓

(with Barcode)Optinal tests• Roughness - - ✓ ✓ ✓

• Hardness 6) - - ✓ ✓ ✓

• Layer thickness - - ✓ ✓ ✓1) Through variation of the grip spacing L2) Drive-in height fixed through fixed grip, i. e. axial alignment in the magazine placement3) Not suitable for foils (not rigid). For specimens with large deformations, only 1 part of the broken specimen is replaced in the magazine in each case4) Requires additional time expenditure. Alternative: additional disposal grippers and e. g. good/bad switch points5) In parallel length or to total length6) HR15T, HR30T, HR45T, HRB with automatic range changing, e. g. dependent on the specimen thickness previously

Automated hardnesstesting

Application

For automatic hardness tests,a hardness testing device forRockwell HR15T, HR30T, HR45T,HRF, HRB, HRC is coupled withautomatic specimen handling ofthe X-linear system.

Data technology

In all systems, specimen dataand test results are printed outand stored, or transmitted via aninterface or a local PC network toa higher-order computer system,for the production of certificatesand for production control.

Portal system

The portal system is based on thesame three-axis principle as thelight portal system, but is designedfor a considerably greater specimenweight. It is supplied in two designs:

• with electro-mechanical drive andshelf magazine

• with pneumatic drive and beltmagazine.

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High-frequency testingmachines (Vibrophores)(with electro-magnetic resonancedrive)

Application

Force or elongation-regulated testsfor determining the oscillationstability in the time, and fatiguestrength range.

• Fatigue tests according toDIN 50100 (Wöhler curve) in thetensile, compression, pulsatingand alternate load range

• Mechanical fracturing testson CT and COD specimens

• Stimulation of oscillationsof the bending specimens

• Time and fatigue-strengthinvestigations on componentssuch as springs, bolts,crankshafts, connecting rods,steering knuckles etc.

• Production and quality controlof components which areexposed to dynamic stressingduring their service life.

• Tests under various environmentalconditions (temperature,aggressive media).

Special features

• Low energy consumption• High test frequencies, short test

times• No adjustm. of excitation air gap

Fatigue Testing Machines

Servo-hydraulictesting machines

Application

These testing machines arepredominantly used to performtensile, compression and bendingtests with complex, dynamic stresssequences.

Special features

• Extremely rigid, practicallyresonance-free load frame withmanually or hydraulicallyadjustable crosshead.

• Continuous rated working cylinderwith highly accurate guidemechanisms thus ensuringmaximum rigidity at all testinglevels

• Precision strain gauge load cells

for continuous operation atmaximum dynamic loading

• LVDT-stroke transducer (installedcentrically in the piston rod) withhigh resolution, linearity and longservice life.

• Freely positionable hydraulic unit• Low noise level through internal

geared wheel feed pump• Optionally water or air cooling

Technical data

See table servo-hydraulic testingmachines (STM)

Measurement and controlelectronics

The digital measurement and controlelectronics Amsler HydroWin® 9600offers connections for externaltransducers and extensiveapplications software.

High-frequency testing machineAmsler HFP 400

High-frequency testing machineAmsler HFP 5

Servo-hydraulic testing machineAmsler HB126/80

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High-Frequency testing machines (HFP)

Series/type Amsler HFP 1 - 5 Amsler HFP 20 - 550• Construction type table top floor standing• Load frame nominal force, kN 1 - 5 20 - 550• Max. force amplitude, kN 2.5 275• Max. elast. spec. deform., mm ± 3 ± 2• Frequency range, Hz 35 - 300 35 - 300• Frequency levels 5 16/5• Working area width, mm 350 530/600• Max. power consum., kVA 2 5

Rotary bending testing machines (UBM)

Series/type AmslerUBM 200 Amsler UBM 2000 • Max. bending moment, Nm 200 2,000 • Load reversal frequency, min-1 50 - 5,000 600 - 3,000 • Max. specimen diameter, mm 25 50 • Max. power consum., kVA 1.6 5.5

Servo-hydraulic testing machines (STM)Standard design1)

Series/type2) HC HB HA• Construction type table top floor stand. floor stand• Load frame nominal force, kN 5 - 25 50 - 1,000 50 - 500• Testing stroke, mm 100 100/250/400 100/250• Specimen length, mm 100 - 700 100 - 1,100 250 - 1,500• Hydraulic power pack

* System pressure, bar 210/280 210/280 210/280* Flow, l/min 4 – 23 9 – 600 9 - 600

• Max. power consum., kVA 2.2 – 11 2.2 – 74 2.2 - 741) Load frames and actuators for higher nominal forces on request2) In the HC and HB serie the actuators are situated in the upper crosshead, in the HA serie

in the lower crosshead

Technical data

See table high-frequency testingmachines (HFP)

Measurement andcontrol system

Measurement and control of thesetesting machines is taken over bythe measurement and controlelectronics VibroWin®.

The data selected by the operatoras well as the set values and actualvalues are digitally displayed on thescreen.

Rotary bendingtesting machines

Application

With the rotary bending test, thefatigue strength of round specimensunder reversed bending stresses isdetermined.

Technical data

See table rotary bending testingmachines (UBM)

Rotary bending testing machineAmsler UBM 200

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Pendulum impact testers

Series/type Zwick 5113 Amsler RKP 450 Amsler PSW 750• Max. impact energy, J 50 150/300/450 300/450/600/750• Angle of decent, º 160/124.4 150 161• Impact speed, m/s 3.46 / 3,85 5.23 5.42• Pendulum form disk (C) box (U) disk (C)• Instrumentation optional optional optional

Drop weigth testers (IFW)

Series/type Amsler Amsler Amsler Amsler Amsler AmslerIFW413 IFW420 IFW513 IFW520 IFW525 IFW530

• Max. height of drop, mm 1,274 2,000 1,274 2,000 2,500 3,000• Max. impact speed, m/s 5.00 6.25 5.00 6.25 7.00 7.67• Standard weight of drop [kg] 17 (3+14) 25 (3+22) 25 (3+22) 25 (3+22) 25 (3+22) 25 (3+22)• Max. impact energy, J 210/500/ 490/784/ 312/1,250/ 419/1,960/ 613/2,000 735/2,000

- (Standard with optional weigth) 800 800 2,000 2,000• Load cell nominal force, kN 50 (other load cells on request)

High-speed testing machines (HTM) Standard design

Series/type Amsler Amsler Amsler Amsler Amsler Amsler Amsler AmslerHTM HTM HTM HTM HTM HTM HTM HTM2012 2020 5004 5008 5020 10002 10004 10020

• Nominal force, kN 20 20 50 50 50 100 100 100• Test speed, m/s 12 20 4 8 20 2 4 20

Impact testing machines

High-speedtesting machines

High-speed testing machinesare used for high test speeds,particulary for rapid-tearing andimpact penetration tests.

With the corresponding equipmenttensile, compression and flexuretests according to DIN 51220, DIN51221, DIN 51223 and DIN 51228under continous, dynamic andalternate load for static, quasi-staticand dynamic load applications arepossible.

Measurement and controlelectronics

The control electronics SpeedWin®

with the user software testXpert®

allows an extensive evaluation of

test results as well as thecreation of test reports anddata administration.

Technical data

See table high-speed testingmachines (HTM)

Pendulum impact tester

With pendulum impact testersCharpy and IZOD impact testsas well as tensile impact testsare carried out.

Construction

• Rigid, twist-free frame withlow-friction pendulum bearing.

• Electromagnetic safety brakeand lifting mechanism for thependulum (from 50 J on)

High-speed testing machineAmsler HTM 10020

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Creep testing machines (DSM)

Series/type DSM 6102 DSM 6100-FForce application by Servomotor SpringType of test creep/relaxation creep/relaxationLoad frame/spring nom. force, kN 50 - 500 5/10/25/50Screw stroke, mm ± 100 ± 100Adjustment speed, mm/min max. 20 max. 40Working area height, mm 1000Max. power consumption, kVA 2 0.45

Measurement andcontrol electronics

• Analog dial display for readingthe absorbed impact energyand angles and intelligent digitaldisplay for the direct reading ofthe absorbed impact energy

• Electronic measurement andevaluation unit ImpactWin forinstrumented impact tests.

• User software testXpert for thetest data administration.

Features

• Easy exchangeability of tubs,supports and counter-supports.

• Exchangeable pendulumhammers for different typesof test and energies.

Technical data

See table pendulum impact testers

Drop Impact Testers

The Amsler drop impact testersare impact test systems for theperformance of impact penetration,notched bar impact and tear testsin the range up to 800 J and 19 m/sor up to 2.000 J and 21 m/s. Morefields of application are opened up

by using temperature chambers,high speed options and varioustest tools.

Measurement andcontrol electronics

Computer-controlled with thecontrol electronics ImpactWin® andthe testXpert® software for the testcontrol, data backup, readout andanalysis.

Technical data

See table drop impact testers (IFW)

Creep testing machines

Creep testing machines are usedfor two tasks:

• For the long period creep test.Here, the strain-time behaviourat constant force and constanttemperature is determined.

• For the relaxation test. Here, theforce-time behaviour at constantstrain and constant temperatureis determined.

The tests can be carried out attemperatures from -196 to +1,200(+1,500) ºC and in environmentssuch as air, inert gas or vacuum.

Drop impact tester Amsler IFW 420

Pendelum impact tester Amsler RKP 450

Pendelum impact tester Zwick 5113

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Ductilitytesting machines

Application

• Testing of the formability ofsheet metal

• Testing of the influences ofsurface treatments, coatingsand lubricants for typical typesof deformation (deep drawing,stretching and forming)

• Test tools for Erichsen- and Olsencupping tests, cupping draw test,Fukui test, Bulge test etc.

Special features

• Simple and fast exchangeabilityof the test tools as e.g. shapingram, deep drawing die, sheetmetal holder, blanking punch,die ring and sheet metal scraper.

• Test tools from previous modelsto be used without restriction ormodification.

• Quiet, clean operation andeasy to transport for the use inlaboratories, offices or seminarrooms.

• Low piston-to-cylinder frictionfor precise measurements andreproducible test data records.

Construction

• Spring-loaded construction withspindle drive and two-positioncontroller.

• Servo-electric drive with centralre-circulating ball screw

Technical data

See table creep test machines(DSM)

Test data acquisitionand test control

With the software CreepWin®

a personal computer (PC) canmonitor and control up to 16machines.

Special features

• Simple, robust and practicallymaintenance-free

• Universally applicable• High long-term stability• Externally controllable• High precision and reliability• Long service life

Ductility testing machineAmsler BUP 200

Creep testing machineAmsler DSM 6100-F

Technical data

See table ductility testing machines(BUP)

Ductility testing machine (BUP)

Series/type Amsler Amsler Amsler AmslerBUP 100 BUP 200 BUP 400 BUP 600

• Max. cupping force, kN 100 200 400 600• Max. sheet met. clamp. force, kN 25 25 30 50• Punching force, kN - 150 250 600• Max. test stroke, mm 80 80 120 120• Max. test speed, mm/min 235 750 750 750• Circular blank diameter, mm 80 170 210 260• Max. sheet met. strip width, mm 120 120 160 260• Max. sheet met. strip thickn., mm 2 4.5 4.5 10• Circ. blank punch diameter, mm - 120 160 220• Test punch diameter, mm 60 75 90-105 100• Max. power consumption, kVA 7.5 7.5 15 20

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Webster pliers

Hardness Testersand Testing Machines

Webster pliers

Portable, easy to operate testingpliers with display of penetrationdepth which can be converted intoRockwell or Brinell hardness.

Sclerograph

Portable hardness testing device forsteel and non-ferrous materials.Optionally available:• Testing anvil for the testing of

small test pieces (mass < 1 kg).

• Device for hardness testing onrollers (diameters 100 - 800 mm)

Hardness Tester Zwick 3106

For the testing of the indentationhardness on plastics, Rockwellhardness on metals, plastics andcarbon materials as well as thehardness of building plaster andasphalt.

It is equipped with a digitaldialgauge and can be expandedfor the data output on a printer.

Rockwell Hardness TestersZwick/ZHR

The different devices of this productfamily are designed for• the classical Rockwell methods

(loading : 60 - 150 kg),• the Super-Rockwell method

(loading: 15 - 45 kg) and the• combination of these methods

(loading: 15 - 150 kg).

These devices are distinguishedby an indentor mounting supportfor hardness testing at hardlyaccessible measuring positionsand guarantee a simple and easy

operation by• automatic test mode• selection of loading weights by

rotary type push-button resp.by touchscreen

• automatic loading and unloading• automatic evaluation including

conversion

Additional features:• preselection of tolerances• robust construction with

backlash-free, ball-bearingmounted spindle

• working area up to a height of292 mm for the testing of largespecimens

• RS 232 interface as standard• manifold standard accessories

(indentors, anvils, hardnesscomparison plates).

• low-cost version with elasticforce load application

Hardness Testers Zwick/ZHV

These Vickers hardness testerscover many different load rangesand have equipments of variouscomfort levels. Thus, for each caseof application customer-specificand suitable devices are available.

Sclerograph Hardness tester Zwick 3106 Rockwell hardness tester Zwick/ZHR

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Hardness TesterZwick/ZHV 10

This device is especially approvedfor the determination of the• Vickers hardness,• Knoop hardness,• Brinell hardness,• Depth of hardness, hardness

penetration and nitriding depthas well as

• the scratch hardness (3212001).

Loading weights from 0,2 kg to10 kg (or to 30 kg) andexchangeable objectives for differentmagnifications and image ranges areavailable for both variants:• With the analog tester (3212001)

the hardness value is evaluated bymeans of hardness tables.

• The PC version (3212003) workswith the user software testXpert®

which is easy to use and whichcan be flexibly adapted tochanging test conditions. Theindentation is measured at themonitor and is evaluatedautomatically. A Master testprogram for Vickers, Knoop and

Brinell hardness tests is availablefor series measurements whichcan be extended for hardnessgradient tests and automaticindentation measurement. Inaddition to manually movable ormotorized compound tables, avariety of further accessories ase.g. clamping devices are available.

Vickers Hardness TestersZwick/ZHV 30 andZwick/ZHV 50

These devices working in a testload range from 9.8 N to 490 N areused for testing the• Vickers hardness and the• Brinell hardness (optional).

They are equipped with dead loadweights and an indentor mountingsupport making them suitable forhardness testing at most flexibletest positions and they are suppliedwith LCD line display or with atouchscreen.

The measuring microscope isprovided with moveable curtains for

the simple acquisition of theindentation diagonal. This valueis transferred to the software bypressing a button and the value ofhardness is displayed automatically.In addition to the input of tolerancelimits standard-conformingconversions and statisticalevaluations are also possible.Available as standard are RS 232interface(s) and a large variety ofaccessories (indentors, anvils,hardness comparison plates).

Universal Hardness TesterZwick ZHU/187,5

These devices are designed forhardness tests according to Vickers,Brinell and Rockwell and for differentload level combinations. They areeasy to operate. The test sequenceis carried out automatically. Ameasuring microscope and amultiline LCD-display are integrated.The conversion of hardness is alsopossible. Indentors, hardnesscomparison plates and specimentables round off the standardaccessories.

Vickers-hardness testing machine ZHV20/Z2,5Vickers herdness tester Zwick/ZHV50Vickers hardness tester Zwick/ZHV10

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Vickers Hardness TestingMachines Zwick ZHV20/Z2.5

The hardness testing device foroptical measurements is integratedin a zwicki testing machine.The built-in load cell measureselectromechanically applied testloads between 2 and 200 N.A CCD-camera is fitted on amicroscope at an angle of 90°.Objective lenses and indentorholding device(s) are integratedin the revolver head so that thechange of positions between thesetting and the measurement ofthe indentation is carried out byturning the revolver. A Mastertest program includes seriestests according to the methodsof Vickers, Knoop and Brinell.Optionally extensions for automaticindentation measurements andfocussing as well as hardnessgradient measurements withmanual or motorized compoundtables are available.

Universal Hardness TestingMachines ZHU2,5/Z2,5

They can be selected with theinstallation of the hardnessmeasurement head to the amaterials testing machine. Thehardness measurement head coversall hardness test methods withindentation measurement as e.g.:• Martens hardness HM

(macro-range),• Rockwell hardness, scales A to K,

N, T as well as HMR5/250,• Ball indentation hardness H,• Vickers depth measurement HVT

and• Brinell depth measurement HBT.

Integrated in the measurementhead are a digital travelmeasurement system (resolution0,04 µm), a load cell (ranges: 2 Nto 200 N resp. 5 N to 2500 N) andan exchangeable indentor.

The particular features are:• Simple ”1-button“-operation• Fast and automatic run-up even

with different specimen heights

• High accuracy and reproducibilityof the test data by high testdata resolution and constanttest conditions

• Determination of additionalcharacteristic material data fromthe force-penetration progression

• Suitable for product-accompanying tests

A supplmentary unit “Optics” hasbeen developed for the hardnessmeasurement head. Thissupplementary unit consists ofa measuring microscope withup to 4 objective lenses and alinear slide unit to ensure that acomponent to be tested is notdisplaced.

The universal hardness testingmachine of this combination is –in addition to the above-mentionedtest methods – able to carry outstandard-conforming hardnesstests according to Vickers, Knoopand Brinell. The combination of thesupplementary unit Optics and thehardness measurement head leadsto extracordinary properties via thetestXpert® intelligence. In additionto the known advantages such asautomated test sequences andsimple adaptation to changing testconditions e.g. the recording of theforce-indentation depth sequence isalso possible with optical hardnesstest methods.

The Master test program developedfor the hardness measurementhead allows to carry out hardnesstests according to Martens,Rockwell and ball indentationhardness as well as Vickers andBrinell hardness according to themethod HVT and HBT (indentationdepth measurement). It isexpandable for Vickers, Knoop andBrinell hardness tests. In additionhardness gradient tests withautomatic indentation measurementand focussing are also possible.

Universal hardness tester Zwick/ZHU187,5 Universal hardness testing machineZwick ZHU2,5/Z2,5

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ZMART –Zwick Modernizationand Retrofit Technology

Modernization package

With the modernization packageZMART.PRO® both electro-mechanical and hydraulic materialstesting machines of differentmanufacturers can be upgraded andbrought to the most recent state-of-the-art. After a modernization theguaranteed spare parts supply formodernized components, the entire

accessory program includingextensometers or specimen gripsand in particular also the mostrecent version of the test softwaretestXpert® are available.

The decision between the purchaseof a new machine and amodernization primarily dependson the value and technical conditionof the machine components to betaken over. Due to the fact that inaddition to the load frame othercomponents can also be usedfurthermore, as e.g.: load cell and

extensometer, the costs for amodernization remain relatively lowcompared to the costs incurred inthe purchase of a new machine.

The modernization packagesare composed of the followingcomponents:• Digital measurement and control

electronics• Test software testXpert®

• Maintenance-free AC-drives• Proportional valves or servo

valves and hydraulic units forhydraulic testing machines

Special features or services ZMART.PRO®

testControl Allround (DUPS)M1) H2) M1) H2) I3)

Connection to• Electro-mechanical testing machines ✓ - ✓ - -• Quasi-static hydraulic testing machines - ✓ - ✓ ✓

• Can also be used without Personal Computer (PC) ✓ ✓ - - -• Up to 3 hydraulic testing machines - - - ✓ -Test data acquisition and display• Test force and crosshead or piston travel resp. ✓ ✓ ✓ ✓ ✓

Connection of:• Analog extensometers (inductive) ✓ ✓ ✓ ✓ ✓

• Analog extensometers (strain gauge system) ✓ ✓ ✓ ✓ ✓

• Incremental extensometers ✓ ✓ ✓ ✓ ✓

• several load cells (changeover via testXpert®) ✓ ✓ ✓ ✓ ✓

Test data storage and processing• Display of maximum force and travel when reaching ✓ ✓ - - -

the test end criterion (without PC)• Optional display of test force or stress, travel and/or ✓ ✓ ✓ ✓ ✓

deformation or strain (only with PC)• Output of XY-curves with the coordinates force/stress, ✓ ✓ ✓ ✓ ✓

travel and/or deformation/strain or test time (only with PC)• Automatic determination and documentation of materials ✓ ✓ ✓ ✓ ✓

characteristic data and statistical data (only with PC)Test sequence and test speed control• Automatic recognition of the test end (specimen break, force- ✓ ✓ ✓ ✓ -

travel or time limit value or number of test cycles reached)• Automatic stop at test end or return to start position ✓ ✓ ✓ ✓ -• Automatic speed changes according to the ✓ ✓ ✓ ✓ -

test program (only with PC)• Test speed control in dependence on the measured ✓ ✓ ✓ ✓ -

force or deformation („closed-loop“-control),only with PC and optional program)

Monitoring of safety limit values• Test force ✓ ✓ ✓ ✓ -• Crosshead- resp. piston travel ✓ ✓ ✓ ✓ -

1) For electro-mechanical testing machines 2) For hydraulic testing machines, 3) Only data aquisition and display

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Services

Customer satisfaction is given toppriority at Zwick/Roell. Therefore,nearly one third of the employeesare active in the service field.Extensive services guarantee thebest use possible and a highavailability of the supplied testingmachines and systems.

Advice and support

Our technically competent andexperienced service personnelsupport the user directly at siteor by phone, fax or e-mail. Detailedinformation may also be lookedup in the internet or may bedownloaded in case of need.

Maintenance and repair

A service contract with individuallyagreed service intervals for a carefuland thorough maintenance andcalibration guarantees the correctand trouble-free operation of thesupplied testing machines andsystems. Whereby it is notimportant which manufacturersupplied the testing machine. Incase of a malfunction, a service-engineer or – technician is quicklyavailable at site. Modern auxiliarymeans such as a telediagnosticservice via modem allow a quickand exact fault localization at anearly stage. Different reactionmodels guarantee the availabilityof a technician within the shortestperiod of time possible.

Calibration serviceaccording to ISO 9000

The Zwick/Roell maintenance andcalibration service is accredited asDKD1)-, UKAS2) or COFRAC3)

calibration laboratory resp. Thus,it is authorized to check the testingmachines and systems at the placeof installation and to issue DKD or

UKAS calibration certificates forthe measured quantities force,extension, energy and hardness.These calibration certificates arenot only recognized within theEuropean Union, but also in almostevery country of the world.

Particular advantage:The technicians of the calibrationservice can, on the occasion of theirservice visit, not only service, adjustand calibrate the Zwick/Roell testingmachines and systems, but also themachines and systems of othermanufactures. This saves time andcosts.

The regular maintenance andcalibration of the testing machinesis also a prerequisite for a qualitymanagement system according toQS-9000 and VDA 6.1.

Hotline – Quick assistancein case of malfunctions

For Zwick/Roell, the perfectfunctioning of the testing machineis very important. Should, in spiteof the high quality standard, anymalfunctions occur on the machineor within the software, thencompetent specialists are availableon the free hotline.

Creation and adaptation oftest programs

With the test software of the Zwick/Roell Group already many differenttest programs can be acquired. Thetest requirements are however notalways standardized. Experts willadapt your existing test programsindividually or will create a new testprogram which is tailor-made tocomply with your requirements.

Seminars

Studies have shown that more thanhalf of the problems with technical

systems are not caused by thetechnology itself, but rather by theuser. A good training of the usershelps to avoid troubles and, as aresult, to reduce the costs.

The Zwick/Roell seminars informabout theory and practice of thematerials and component parttesting, the evaluation and thevaluation of the test data, testresults and the operation andmaintenance of the testing devices.These seminars either take placedirectly at the user’s place or at thelocations of Zwick/Roell companiesor representations.

Support line – Assistancefor operation andapplication

Alternatively to the visit of a seminaror to the service visit of a technicianat site, you can talk to our expertson the support line – against charge– whenever you have any questions.They will assist you with theadaptation of the test software,with the creation of test programs,when having questions regardingthe operation of the software orthe machine and they will give youan application-specific support.

Spare parts

Standard components are mostlyavailable on stock and will be sentto you by courier service on theday of order. Special components,not being carried on stock, willbe manufactured ”just in time“by means of the latest productiontechnology.

1) DKD: Deutscher Kalibrier-Dienst(German Calibration Service)

2) UKAS: United Kingdom AccreditationService

3) COFRAC: Comité Francais d´Accreditation