Material testing
Steel, aluminium, ceramic or plastic – all materials can show signs of wear over time or already have manufacturing-related defects. Undesirable anomalies and damage can, however, be identified and eliminated at an early stage by means of comprehensive material testing.
Table of contents
What is material testing?
Material testing includes a series of methods with the goal of determining the characteristic parameters and properties of material samples or components. The samples are tested using various test methods - mechanical, thermal or chemical - and checked in relation to their purity, freedom from defects or load-carrying ability. The methods for material testing can be divided into three main categories: destructive, non-destructive and limited destructive methods.
Material testing
at Quality Analysis
At Quality Analysis, the focus is on your requirements. We provide not only the data, but also practical solutions and recommendations that help you to improve continuously your products and processes and ensure their functionality. We undertake the necessary analyses in our accredited laboratory or on site in your facility – even during ongoing production.
- Use of the latest test methods for destructive and non-destructive material testing
- Detailed analyses using non-destructive technologies such as industrial computed tomography and optical metrology
- Reliable damage analysis for the determination of the causes of damage and quick, precise results
- Very wide range of destructive test methods such as microstructure analysis, hardness testing, as well as weld seam inspection and solder joint inspection
- Practical test reports that provide you with specific answers and reliable solutions
- Accredited laboratories for component testing as per DIN EN ISO/IEC 17025 and DIN EN ISO 9712
Why is material testing so important?
Material testing is used to inspect finished components as well as to test material samples. In this way, different materials can be tested for purity, load-carrying ability and freedom from defects. This information is crucial for industrial production processes to be able to make reliable statements about the quality or the condition of products. In this way, possible problems can be detected at an early stage and any downtime or loss of production avoided.
Detailed insights by means of material testing
Material testing also permits the continuous optimisation of materials and production processes by providing detailed insights into material behaviour in specific conditions. This deep understanding of material characteristics is essential for the development of innovative products that meet increasing requirements on performance, durability and sustainability. Overall, material testing is not only a means for the detection of defects and quality assurance, it is also a driver for innovation and progress.
Methods of material testing
Each method provides different insights into the material characteristics and is essential for material selection and optimising components. Undertaken in specialised laboratories, the precise measurement and analysis of the test results permits a sound evaluation of the materials. This evaluation is indispensable for the development of products and ensuring their quality and durability. There are numerous different test methods that provide, among other aspects, information about load-carrying ability, wear resistance and fracture toughness, as well as material defects such as inclusions, cracks or shrinkage cavities.
Microstructure analysis
By analysing the microstructure of a material, important information about its characteristics such as microstructure states, grain sizes and deformation, hardness, strength and ductility can be obtained. These analyses help during the evaluation of the treatment and processing of the material.
Hardness testing
Hardness testing is one of the basic methods of measuring the resistance of a material to deformation or penetration. It provides information about the strength and wear resistance of the material and helps to prevent possible material failure.
Weld seam inspection
The application of heat can make metals brittle. Weld seam inspections are therefore crucial for the evaluation of the quality and integrity of welded joints. They can include both destructive and non-destructive methods for the identification of deformation, cracks, pores or inclusions.
Tensile/compressive/bending testing
Tensile testing forms part of the classic repertoire of destructive material testing, as do compressive and bending testing. With modern test equipment, comprehensive knowledge of the relevant standards and extensive practical experience, our experts ensure the individual tensile, compressive and bending tests are undertaken correctly.
Damage analysis
During damage analysis, it is analysed why a material or component has failed. The goal is to identify the cause of the damage to prevent future failures and improve material selection, as well as the design.
Thermal analysis
Thermal analyse involves methods such as thermogravimetry (TGA) for the analysis of the behaviour of materials subject to thermal effects. Thermal analysis provides insights into melting points, transition temperatures and thermal stability.
Surface analysis
During surface analysis, the outer layers of a material are analysed for surface roughness, texture and coating quality. Methods such as scanning electron microscopy (SEM) can detect surface defects that could degrade the performance or the appearance of a product.
Chemical analysis
Chemical analysis permits the exact determination of the chemical composition of a material. Techniques such as spectroscopy (e.g. FTIR or RAMAN spectroscopy and SEM-EDX analysis) are crucial for the identification and quantification of contamination and alloy elements.
Different material tests:
destructive, non-destructive, static and dynamic
The decision between destructive and non-destructive material testing is affected by various crucial factors. While destructive test methods are of major importance, particularly in material development, research and quality control, non-destructive test methods are often used for the inspection and maintenance of critical structures and components.
Destructive material testing
Destructive material testing permits the precise determination of mechanical characteristics such as the strength, ductility and hardness of materials. Although these methods provide valuable data, they cause damage to the samples tested or even completely destroy them. They are therefore relevant, above all, for monitoring production processes by means of random sampling, for example for the evaluation of the quality of welded and soldered joints as per specific standards.
Non-destructive test methods
Non-destructive material testing permits the identification of material defects or characteristics, without damaging the material. In this way, comprehensive analyses of material integrity can be undertaken, without removing the components from their operational context or even needing to replace them. This method provides cost-efficient, practical quality assurance for numerous industrial areas, without degrading the production process.
Static test methods
Along with the differentiation between destructive and non-destructive test methods, static and dynamic methods also play an important role in material testing. Static methods concentrate on the measurement of the reaction of materials to constant or slowly changing loads. Typical examples are tensile, compressive and bending tests that provide information about basic mechanical characteristics such as strength, elasticity and fracture behaviour with a constant load. These tests are essential for determining the suitability of a material for applications in which the material is subject to static loads.
Dynamic test methods
Dynamic test methods, on the other hand, analyse the behaviour of materials subject to quickly changing or cyclic loads. Fatigue tests and vibration analyses fall into this category. They are crucial for assessing the endurance strength and the fatigue behaviour of materials, particularly in applications where materials are subjected to repetitive loads, for instance in the automotive or aerospace industry. These dynamic tests help with the prediction of the service life of components and ensure that they withstand the requirements in actual use.
In summary: material testing
Material testing plays a crucial role in quality assurance and product development with a series of specialised methods – including destructive and non-destructive tests – that detect material defects at an early stage and provide detailed insights into the physical characteristics of materials such as steel and plastic. These essential analyses aid the optimisation of production processes and contribute significantly to ensuring safety.
