Component testing

Component testing is an important business area at SLV Halle GmbH, and testing complete components – especially including welded structures – takes years of extensive experience.

Dynamic testing on complex structures and structural components in railway vehicles and mechanical engineering as well as component optimisation in automotive and construction using technical testing are two areas especially worth mentioning. State-of-the-art digitally controlled testing technology on the large test bench at SLV Halle GmbH allows component load testing with up to four channels. Servo-hydraulic test cylinders with numerical programming support a variety of testing methods on unsupported structures

Tests on components mainly subjected to static and cyclic loading at SLV Halle GmbH

Requirements on component and assembly manufacturing and testing are very broad in the wide variety of industrial segments. Compliance with standards applies beyond regulated areas, as unregulated production is often subject to specific customer specifications where certain standards and regulations still apply. Even considering the achievements of recent years in harmonising regulations such as Eurocode, we are still a long way from harmonising the many industries as yet unaffected. Requirements on materials, components and structures are often less than obvious in the varying regulations, especially in multidisciplinary projects. Gaining a final clarification as to a component’s actual load capacity and whether or not it is fit for purpose in the given application often involves component prototyping and/or testing. SLV Halle GmbH has a highly versatile testing lab for this type of testing, which is capable of simulating and testing a wide variety of load cases that would arise in real-life application. The testing equipment comprises a spring-mounted support foundation of 450 tonnes, a freely modifiable carrier and frame system, a variety of hydraulic cylinders for static and cyclic testing for loads ranging from 100 kN to 1,000 kN, and a pressure transducer for internal static and cyclic pressure tests.

Rail joints (such as flash and aluminothermic welds) on various profiles are regularly tested with cyclic loads for fatigue strength in welding approval processes and procedure audits. The test may take more than two weeks per rail to achieve the five million load cycles required, unless of course the test piece fails beforehand. (Test rig and break profile on the right)

Rail joints (such as flash and aluminothermic welds) on various profiles are regularly tested with cyclic loads for fatigue strength in welding approval processes and procedure audits. The test may take more than two weeks per rail to achieve the five million load cycles required, unless of course the test piece fails beforehand. (Test rig and break profile on the right).

Static tests are usually aimed at determining load capacity in assemblies and structures.

Crane handling was simulated to test the maximum loads on cranable blank pallets as shown in the test rig on the right. Centre and off-centre loads up to 40°t can be applied and tested as based on DIN EN 13155 using the hydraulic cylinder.

Especially high quality demands need to be observed, preserved, and possibly monitored on joints in pressure vessels and pipelines that may be subject to long periods of pressure, soil load and corrosion.

The testing hall performs internal pressure tests at pressures up to 200 bar. The increased potential risk means that the pipelines need to be tested to failure in burst tests, which involves special safety precautions. Pressure threshold tests may be applied in combination with a force-applying hydraulic cylinder to simulate the constant load of soil above the pipe (see figure).

Finally, many component tests have shown discrepancies between calculation and reality, even with FEM analysis, weld simulation, and similar methods playing an increasing role in steel and mechanical engineering. Component testing on real objects in real-life scenarios is often unavoidable in testing and using materials and assemblies to their limits.

Current areas of activity at SLV Halle GmbH