MSRC instituteofaviation - CBMK

MSRCMateriills &Strudures Research Center

instituteofaviationwarsaw, since 1926

STRUCTURAL TESTS

Static and fatigue tests• Static and fatigue tests of complete structures or components,• Functional tests of unloaded and loaded structures including load, displacement and

strain measurements,• Stiffness evaluation,• Static and quasistatic tests of turboengine shafts or other axially symetric structures

(tension/torsion loads), also at elevated temperatures,• Testing of composite structures.

Dynamictests:• High-cycle resonance fatigue tests and vibrations resistance tests (e.g. of turbine blades),• Impact hammer modal tests of structural elements.

Other tests:• low-revolution wear testing offan blades and discs - test rig"Windmill'~• High-energy impact tests of structures using an air gun (diameter of projectiles up to

220 mm, weight - up to 15 kg, velocity - up to 300 m/s) with high speed camerarecording and strain measurement.

The laboratory conducts tests according to test programmes designed by the client as wellas providing comprehensive testing services which include:• Developing test programmes including defining:

- test objectives- test specimens,-test load spectrum (levels, frequency, numberofcycles),- calibration of strain gauges,-load control mode,- inspection methods and intervals,- proceduresforthe evaluation and presentation oftest results.

• Design and manufacturing of test rigs,• Assembly and installation oftest rigs and tested objects,• Test instrumentation (strain gauges, displacementtransducers)• Calibration of strain gauges,• Testexecution,• Test report preparation,• Analysisof test results.

Institute of AviationMaterials & StructuresReseaKh Centreal. Krakowska 110/114,02-256 Warsaw, PolandPhone: +48 22 868 51 06, + 48 22 846 0011 ext. 246Fax:+48 22 868 56 80e-mail: [email protected], www.cbmk.pl

AB 792 •~ Achi ving Competitive Excellence

The United Technologle~ Jpe'atmg Sv~terr

mailto:[email protected]

http://www.msrc.pl,

http://www.cbmk.pl

MSRC instituteofaviationwarsaw, since 1926

Materiills &Strudures Research Center

STRUCTURAL TESTS

Test type Objects and elements Basic parameters Test temperature Equipmenttested and load range

Static and fatigue tests length: Axial force: Upto 500'( Test machine Schenck-Pegasusof aircraft engine shafts up to 3.6 m up to 1334 kN (in tested area) for simultaneous torsionor other axi-symmetric Diameter: Torsion: and tension or compressionelements up to 1.2 m up to 452 kNm ~ loads

~

Frequency: ~ \up to 1Hz

Static and fatigue tests Objects up to: Forces: up to 200 kN Am6ient temperature 24 channel electro-hydraulicaccording to individual 20mx10m Displacements: (possible local heating test system Edyz/MTSrequirements specified upto 1000mm ofthe structure) with MTSAero 90 controllerby the customer (including Strain:design and manufacturing up to 60000 ~m/m

.___

I~ 3 single channel load framesof test rig). Functional tests Frequency: -- (MTS)with controllersof structures' mechanisms. upt050 HzStiffness evaluation. \High cycle resonance Turbine and compressor Frequency: Ambient temperature 2 electrodynamic shakersfatigue tests and vibration blades and other elements up to 5000 Hz. with control and dataresistance tests Force: acquisition systems

\ up to 1350 kG.Acceleration: \upto 120g

low cycle strength and E.g. fuel tubes (straight or Deflections: Up to 200'( 3 single channel load framesfatigue tests of aircraft bended) with diameter: upt0200mm. (MTS)with controllersengines elements up to 40 mm and other Force: up to 10 kN 1--------elements Frequency:

upto s Hz.»>\

low-revolution wear testing A set of fan blades mounted Rotational speed: Ambient temperature Special test rig - Windmilloffan blades and discs on the disc. upt050 rpmof aircraft engines Diameter:

up to I m.

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MATERIAL TESTS

Mechanical testing of metallic materials• Static strength tests (tension, compression, bending),• Strain/load-controlled low& high cyclefatigue tests,• Creep tests.

We are able to prepare specimens for tests in Machining Workshop (according to the ASTMstandards or other standards requested by the client).

AB 792 •~ Achi' ving Competitive Excellence




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http://www.cbmk.pl



MATERIAL TESTS

Test type Specimens and tested Load range Test temperature Equipmentelements ... ~

Low Cycle Fatigue tests (LCF), Specimens in accordance Tension and compression upto 900'C

~26 test rigs (MTS 310, MTS 810,

strain or load controlled with ASTM or other load: up to 250 kN (1600'F) Instron servo-hydraulic)standards (length up to Frequency: up to 10Hz

~500mm) \--

High Cycle Fatigue tests Specimens in accordance Tension and compression upto 900'C 26 test rigs (MTS 310, MTS 810,(HCF) with ASTM or other load: up to 250 kN (1600'F) Instron servo-hydraulic)

\ standards (length up to Frequency: up to 60 Hz ------100mm)~

Static strength tests Specimens in accordance Tension and compression upto 900'C 14 test rigs (MTS 810, Instron(tension, compression, with ASTM or other load: up to 250 kN (1600'F) servo-hydraulic)bending) standards (length up to

\ 800mm) \Creep tests, Stress Rupture Specimens in accordance Tension load: up to 1100'C 36 test rigs (creeps), including

with ASTMor other upto50 kN (2000'F) 14 with lift to cycle testsstandards (length up to (LCF Long Dwell)150mm)



Institute of AviationMaterials & StructuresReseaKh Centreal. Krakowska 110/114,02-256 Warsaw, PolandPhone: +48 22 868 51 06, + 48 22 846 0011 ext. 246Fax: +48 22 868 56 80e-mail: [email protected], www.cbmk.pl


http://www.msrc.pl,

http://www.cbmk.pl



NONDESTRUCTIVE TESTS

Weoffer:• tests offull structures, components and their elements,• detection and definition/diagnostics?oftechnological and exploitation defects,• detection of defects such as: material discontinuities - external and internal (blisters,

cracks, inclusions, delaminations,laps, cold shuts, leaks, welded joints defects, etc.),development ofmetodologies and test programmes at different stages ofthe production

• process in the industrial, field and laboratory environments,temporary tests and non-standard non-destructive condition diagnostics, including

• preparation ofmannualsandtechnical documentation,• development and organisation oftraining courses.

MagnetictestsScope:• Detection of surface and subsurface defects offerromagnetic materials.

Equipment:Defectoscope yoke Y6 Magnaflux, Parker, Bycosin magnets, f1uorescents and blackmagnetic inkMagnaflux, UVand white light, magnetic indicator strips, references.

UltrasonictestsScope:• Detection of internal material discontinuities and identification of locations,

configurations and sizes of discontinuities,• Ultrasonic thickness measurements.

Equipment:GEInspection Technologies Phasor XSdefectoscopewith technical probes and references,Thickness Gage PVX.

Penetrant testsScope:• Detection of open surface discontinuities of non-porous materials: metallic and non-

metallic.

Equipment:Magnaflux penetrants, UVand white light, light meters, references





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NONDESTRUCTIVE TESTS

Visual testsScope:• Detection of surface discontinuities and shape defects of the elements using optical

instruments,• Assessment of the surface quality,• Quality control after rep air.

Equipment:Equipment used for fiber endoscope testing {OLYMPUSIF-4D,camera Olympus, monitorJVC}.

EddycurrenttestsScope:• Testing of materials with electrical conductivity,• Detection of surface and subsurface defects, coating thickness measurements,

comparative structural studies.

Equipment:GE Inspection Technologies Phasec 3d and Institute Dr Forster defectoscopes with sets ofspecialized probes and references for defects, conductivity and the corrosion degree.

RadiographictestsScope:• Detection of internal material defects,• Volumetric testing of objects,• Testing of glued, welded and soldered joints,• Verification testing of assemblies, testing of electronic components and subassemblies.

Equipment:(omputerTomograph system vltomelx L240 GEInspection Technologies.

X-raydiffraction testingScope:• Measurement of residual stresses in the samples provided by the client,• Measurement of stresses at points of construction, facilities, etc.,• Measurements ofstress"in situ':

Equipment:X-raydiffractometer Xstress3000 with a goniometer G2.


AB 792 •~ Achieving Competitive Excellence



http://www.msrc.pl,

http://www.cbmk.pl



MATERIAL PROPERTI ESTESTS

Capabilities:• Testing of materials structure,• Testing of materials surface including chemical composition analysis,• Fractographytests,• Material properties measurements.

Fractography - SEM• Testing of metallic and non-metallicspecimens,• Veryhigh resolution images ofa sample surface.

Scope:• Material tests: surface observations using SEand BSEdetectors, determination ofthe

coating thickness,• Microscope fracture examinations: detection of contaminants, microcracks, crack

sources, quantitative examinations of the structure of fractures and determination ofmaterial homogenity.

Equipment:Scanning Electron Microscope Zeiss EVO25 MAwith BSEand SEdetectors.

Chemical composition analysis - EDXScope:• Chemical composition analysis of specimens,• Material identification,• Identification of contaminants,• Determaination ofthe relative element concentration on the specimen'ssurface.

Equipment:EDXdetector: XFlash5010 Bruker,Energy resolution 125 eV.

Metallography:Scope:• Metallographic qualitative and quantitative tests, such as grain size evaluation, non-

metallic inclusion size, phase volume fraction, coating thickness.Metal/ographicspecimenspreparationEquipment:• Cutting machine with the functions of manual and automatic cutting, cooled bywater,• Mounting press for specimens with max dlametere 40 mm,• Grinding- polishing machine capable of preparing up to 6samples ata time.

MicrostrudureanalysisEquipment:• Metallographic microscope Neophot 2, magnification range SOx- 2000x.

Institute of AviationMaterials & StructuresReseaKh Centreal. Krakowska 110/114,02-256 Warsaw, PolandPhone: +48 22 868 51 06, + 48 22 846 0011 ext. 246Fax:+48 22 868 56 80e-mail: [email protected], www.cbmk.pl •~ Achi ving Competitive Excellence



http://www.msrc.pl,

http://www.cbmk.pl



MATERIAL PROPERTI ESTESTS

Surface roughness testsEquipment:Surface roughness tester Mitutoyo SurfiestSJ-301• Drive unit: X-axis: measuring range: 12.5mm,• Measuring speed: 0.25, 0.5 mm/s,• Detector: range: 350~m,• Detecting method:tactile measurement,• Measuringforce:0.75mN,• Stylustip:diamond(60ol2~mR},• Evaluation parameters: Ra,Ry,Rz,etc.

Toughness testsEquipment:Portable Hardness TesterMitutoyo• Measurement in leeb Dlscale, posibilityto convertto HV,HB,HR(, HRBscales,• Maximum surface roughness of the sample Ra10~m, thickness greater than 5 mm.

Innovatest Hardness Tester• Vickers HardnessTester• load range:

• 0.02 -0.1 KgfmicrohardnessVickers,• 0.2 - 5 KgfVickers hardness at low loading,• 10 - 30 KgfVickers hardness.

Impacttests• Testscan be conducted at elevated temperatures in the range of -196°( +400

(

• (harpy impact tests can be performed on standard 10xl0x55mm as well as reducedspecimens 7.5xl0x55mm and 5xl0x55mm

We are able to prepare specimens for tests in the Machining Workshop (according to ASTMstandards or other requested by the client).

Equipment:Pendulum (harpy ImpactTester• (omplieswith PN-ENISOl48-1, PN-EN10045 and ASTME23standards,• NISTverification ofthe current ASTME23standard,• Pendulum energy300J.


The United Technologle~ Ope'atmg Sv~terr


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PREPARATION OF SPECIMENS

Scope:• Preparation of specimens for:

• strength tests (Static Tension , Creep, Impact, Stress Rupture),• fatigue tests (low and high cycle fatigue),

• Machining of to ugh materials used in aircraft engines, e.g. nickel ortitanum alloys,• Specimens are machined according to international standards (e.g. ASTM) and according

to specifications provided by the client.

Equipment:• LatheCNCAVIATurn35,• Milling machine CNC3axing FNE40 N,• Shaft grinder RUP280x500,• FlatgrinderFSG1640-ADII,• EDMmachine with drilling adapter BP-09d,• EDMmachine Mitsubishi BA8,• Two-column band saw PTS400.

Institute of AviationMaterials & StructuresReseaKh Centreal. Krakowska 110/114,02-256 Warsaw, PolandPhone: +48 22 868 51 06, + 48 22 846 0011 ext. 246Fax:+48 22 868 56 80e-mail: [email protected], www.cbmk.pl •~ Achi !ving Competitive Excellence



http://www.msrc.pl,

http://www.cbmk.pl



DESIGN AND ANALYSIS SERVICES

The range of services includes:• Analysis of isotropic and composite structures (including aircraft structures, windshields

and others) subjected to foreign object impact with the use of LS- DYNA, including birdstrike simulations (ALEand SPHmethods),

• Fatigue analysis of aircraft structures, including load spectra development (based on thein-service load measurement),

• Developing test specifications for static and fatigue tests of aircraft structures,• Crack propagation analysis of metallic structures (20 & 3D) with the Finite Element and

Boundary Element Methods (ANSYS10, FRANC2D,FRANOD, AFGROW,NASGRO),• Designing test rigs for the purposes of Structural Testing Laboratory including strength

analysis with the useof the Finite Element Method,• Static Finite Element Analysis (linear, nonlinear),• Comprehensive research services, from test rig design and coordination of test rig

manufacturing conducted by approved subcontractors to the final test report.

Software used for analysis:• LS-DYNA• ANSYS• FRANC2Di 3D• AFGROW• NASGRO• MSCPATRAN/NASTRAN• MSCMARC

Institute of AviationMaterials & StructuresReseaKh Centreal. Krakowska 110/114,02-256 Warsaw, PolandPhone: +48 22 868 51 06, + 48 22 846 0011 ext. 246Fax:+48 22 868 56 80e-mail: [email protected], www.cbmk.pl •~ Achieving Competitive Excellence



http://www.msrc.pl,

http://www.cbmk.pl



OPERATIONAL TESTS

Equipment:Real-Time (ontroller NI (ompactRIO-9022:• Embedded controller runing LabVIEW Real-Time for deterministic control, data logging,

and analysis,• 533 MHz processor, 2 GBnonvolatile storage, 256 MB DDR2memory,• Dual Ethernet ports with embedded Web and file servers for remote user interfacing,• Hi-Speed USBhost portfor connertlon to USBflash and memory devices,• RS232serial portforconnection to peripherals; dual9 to 35VD(supply inputs,

-200( to 55 O( operating temperature range.

Strain gauge measurements:• Strain gauge measurements offlight loads,• Stressand strain measurements in constructions, facilities, machines, etc.,• Load, strength and fatigue analysis.

Simultaneous Bridge Module N19237:• 24-bit resolution, ±25 mVN analog inputs with RJ50connectors,

4 simultaneously sampled analog inputs; 50 kS/s maximum sampling rate,• Programmable half- and full-bridge completion; up to 1OVinternal excitation,• Smart-sensor (TEDS)compatible,• l,OOOVrms transient isolation,• -400( to 700( operating range.




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OPERATIONAL TESTS

Vibration measurements and analysis:• Flightvibration measurements,• Vibration measurements of vehicles, floating objects,• laboratory measurements of vibration,• Vibration measurements of civil engineering constructions,• Vibration measurements of working machines, rotating equipment, installations,• Vibration analysis,• Vibro-acousticanalysis,• Vibration isolation of machines and equipment,• Vibroacoustic diagnostic.

Equipment:• 24 simultaneously sampled vibration-optimized analog inputs at upto 102.4 kS/s,• Frequency range: -O,5Hz-10kHz,• Measured acceleration range: +/- 50g,• O'Cto50'Coperating range,• AC/OCpower supply.

Noise measurements:• Environmental noise measurements,• Aircraft noise measurements (inside and outside the aircraft),• The noise measurements of machinery and equipment,• Traffic noise measurements.

Objectives:• Assessmentofthe level of noise and its environmental impact,• Reduction of noise.

Institute of AviationMaterials & StructuresReseaKh Centreal. Krakowska 110/114,02-256 Warsaw, PolandPhone: +48 22 868 51 06, + 48 22 846 0011 ext. 246Fax:+48 22 868 56 80e-mail: [email protected], www.cbmk.pl •~ Achi',ving Competitive Excellence



http://www.msrc.pl,

http://www.cbmk.pl


Milterills &Strudures Res!irch Center

VIBRATION TESTS

Measurements and analysis of structural dynamics:• Vibration measurements and analysis.• Resonant tests - measurement of modal parameters of structures - frequency, modal

mass and damping, and modes shapes.• Calculations and verification of vibration properties of structures.• Investigation into the aeroelasticcharacteristics of aircraft (verte).

Measurement range:• frequency: 0.1 Hz-50kHz,• amplitude: 0.01g-50g.

Equipment:• 256 channel system LMS.• 300 light accelerometers (from 2g).• Contactless vibration measurements using laser unit 3D with software

PSV-500 Polytec.• 8 shakers Fmax= 1600N.• LMSsoftware for measurements analysis.

Institute of AviationMaterials & StructuresReseaKh Centeral. Krakowska 110/114,02-256 Warsaw, PolandPhone: +48 22 868 51 06, + 48 22 846 0011 ext. 246Fax:+48 22 868 56 80e-mail: [email protected], www.cbmk.pl •::s ,hi ving Competilive Elcellence

AB792 The Unlled Technologies Opera n9 System


http://www.msrc.pl,

http://www.cbmk.pl


Milterills &Strudures Res!irch Center

INVESTIGATIONS INTO TH EAEROELASTIC CHARACTERISTICSOF AIRCRAFT

Scope of research:• Ground vibration tests (GVT).• Determination offlutterspeed and shape based on the results ofGVT.• Calculation offree vibrations and fI utter using the FEmethods.• Preparation offlutterflighttests programs.• Execution offlutterflighttests.• Supporttowards the certification of new or modified aircraft.

Software:• MSC.Patran, Siemens FEMAP.• MSC.Nastran.• JG2 (lPPT PAN).• ZAERO(ZONATechnologies Inc.).• SAF(Subsonic Aerodynamic Flutter).

MP-02 ··Czaj ka··wariant 240

AntYSYMetryczna posta~ ruchu dla:k=O_4S0'f=11_88Hzg=0.0061

EAS=283kM/h'faza = 270"

Institute of AviationMaterials & StructuresReseaKh Centeral. Krakowska 110/114,02-256 Warsaw, PolandPhone: +48 22 868 51 06, + 48 22 846 0011 ext. 246Fax:+48 22 868 56 80e-mail: [email protected], www.cbmk.pl •::s ,hi ving Competilive Elcellence

AB792 The Unlled Technologies Opera n9 System


http://www.msrc.pl,

http://www.cbmk.pl

MSRC instituteofaviation - CBMK

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