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Flaga Unii Europejskiej
KPO

Materials testing

Materials testing

Strona główna Offer Testing services Materials and structures testing Materials testing
Strenght tests
Physicochemical tests
Chemical tests
Non-destructive tests
Environmental tests
Qualification tests of composite materials

We have a high potential in the field of material testing, enabling the determination of their structure, properties, strength characteristics or detection of defects.

We perform following comprehensive tests:

  • mechanical,
  • physicochemical,
  • non-destructive,
  • environmental,
  • chemical.

We test a variety of materials, including:

  • metal,
  • composite,
  • made of plastics.

We perform analyzes using state-of-art testing equipment, in accordance with international standards, using both standardized instruments as well as instrumentation designed and manufactured by us, tailored to the individual needs of the Customers.

Strenght tests

We have a tremendous capacity to perform material strength testing using state-of-the-art universal axial servo hydraulic fatigue machine sets from renowned MTS and INSTRON brands, creep-testing machines, impact hammers and hardness testers.

We perform material tests:

  • metallic,
  • composite,
  • made of plastics.

Strength tests – certificates:

We have the accreditation of the Polish Center for Accreditation AB 792, received as confirmation of the compliance of the work performed in accordance with the requirements of the PN-EN ISO/IEC 17025 standard in the scope of:

  • high and low cycle fatigue tests (HCF and LCF);
  • static tensile tests at room temperature and elevated temperatures and creep tests;
  • non-destructive testing:
    • visual,
    • penetration,
    • magnetic-particle,
    • ultrasonic,
    • eddy current;
    • structural.

We have obtained Pratt & Whitney mechanical test certificates for the following tests execution:

  • creep test,
  • high-cycle tests,
  • low-cycle fatigue tests.

We meet the requirements of the ACE quality system at the “Silver” level and the ISO 9001 standard.

Static tensile, compression, shear and bending tests are among the basic strength tests used to determine the mechanical properties of the materials. Stress-strain characteristics or bending diagrams make it possible to determine such parameters as Young’s modulus, yield strength, short-term strength and elongation, for example.

Static tests – testing capabilities

We perform static strength tests (tensile, compression, bending) of metallic materials using samples according to ASTM or other standards.

We perform comprehensive tests of composite materials, including those intended for aviation structures. The tests are carried out using state-of-art testing equipment in accordance with international standards. We have PCA and NADCAP accreditation in the field of testing non-metallic materials.

The tests are performed at temperatures from -130°C to 315°C, with a maximum load of 250 kN.

We perform following tests:

  • material properties,
  • laminates,
  • knuckle joints,
  • glues,
  • fillers and sandwich structures.

Creep tests, i.e. the process of slow increase of deformations of the material subjected to long-term constant load, are an important source of information in the assessment of material durability. They are performed on creep-testing machines in which the uniaxial strain of the sample is gravitationally obtained by means of calibrated weights hung on the arm of the creep-testing machine.

Creep tests – testing capabilities

Our equipment includes 36 test stations – creep-testing machines, enabling three types of tests:

  • with deformation registration,
  • with time to break registration,
  • cyclic tests (LCF Long Dwell) on 14 stands using lifts.

The deformation of the samples is recorded using high-temperature extensometers. We supervise and record the test using a computer system in real time.

Our laboratory, due to the long duration of testing, is equipped with a UPS voltage maintenance system and air-conditioned rooms with temperature and air humidity recording.

Type of examinationDimensions of the tested samplesLoad rangeTest temperatureTesting equipment
crawl ASTM E139 ASTM E292 ISO 204length up to 150 mmtensile forces up to 50 kNup to 1100°C36 stands (creep-testing machines)

Impact resistance tests are tests that characterize the material’s resistance to cracking under dynamic load. Performed to determine the effect of load speed and strain on the mechanical properties of materials, they define features impossible to determine by static tests.

Impact resistance tests – testing capabilities

To perform impact resistance tests, devices are used that allow the application of a large force in a short time, the so-called impact hammers. In addition to the standard Charpy hammer, we also have its instrumented version, thanks to which it is possible to determine not only the impact work, which is a measure of the material’s resistance to cracking, but also to determine the characteristics of the destructive force as a function of time.

We have special digitally controlled chambers, designed to perform tests on samples with reduced or elevated temperature – a cooling chamber (samples cooled to -180°C) and a heating chamber (tests up to 300°C).

We test both metallic and composite materials.

Type of testingDimensions of the tested samplesLoad rangeTest temperatureTesting equipment
impact resistance10x10x55mm
7.5x10x55mm
5x10x55mm		pendulum energy up to 450 Jfrom -180°C to 300°CCharpy Proeti impact hammer 300 J,
instrumented Charpy Lab Test CHK 450 J-I impact hammer – 450 J-I
impact resistance ASTM D7136 energy range from 0.59 J up to 1.8 kJ
impact speed 0.77 – 24 m/s
drop height 0.03 – 29.4 m		 Instron CEAST 9350 Drop Tower

Hardness tests, i.e. material resistance to local plastic deformations under the influence of concentrated pressure in the form of an indenter with a specific geometry, are used in material science practice due to their simplicity and speed of measurement. Depending on the type of material being examined, appropriate methods and measurement scales are used.

Hardness tests – testing capabilities

We offer measurements using the following equipment:

  • Nexus Innovatest hardness tester with the following ranges:
    • 0.02 – 0.1 kgf Vickers microhardness,
    • 0.2 – 5 kgf Vickers hardness at low loading forces,
    • 10 – 30 kgf Vickers hardness;
  • Falcon Innovatest digital hardness tester with a range of 0.001-31.25 Vickers hardness with the possibility of automatic measurements;
  • Zwick Roell hardness tester with ranges:
    • 10 kg,
    • 60 kg,
    • 100 kg,
    • 150 kg Rockwell hardness;
  • portable Mitutoyo hardness tester – Leeb scale with the possibility of conversion to the HV, HB, HRC, HRB scale.

We test metallic and composite materials.

Fatigue is a process of decreasing the strength properties of a material subjected to long-term cyclic loads, which in turn leads to the destruction of the structure. Two characteristic phases of the fatigue process are the initiation of cracks and their development and destruction of the object. Fatigue strength is the highest stress amplitude at which the material does not fail.

Fatigue tests – testing capabilities

For fatigue tests, we use 30 test stands, the load range of which is in the range from 500 N to 250 kN. We test samples of various geometry and dimensions, made of both light alloys and durable alloys for aircrafts.

The tests performed in the temperature range from -180°C to 1500°C fully cover the demand on the global market of fatigue tests, especially for aircraft alloys. These capabilities result from specially designed sample gripping systems, temperature controllers and properly selected furnaces. Cooling of extensometers for strain measurements is carried out with air or water.

The full range of fatigue tests performed includes:

  • low cycle force (LCF) controlled,
  • high cycle force (HCF) controlled,
  • strain controlled low cycle force (SCLCF),
  • fracture mechanics (KIc, da/dN),

All tests combined with the capability of their performance at temperatures up to 1500°C place the Institute at the forefront of testing centers in the world.

We perform tests in accordance with the accepted standards, including:

  • ASTM,
  • E606,
  • ASTM,
  • E466,
  • ASTM E399,
  • ASTM E647 da/dN and according to customer specifications.

In order to meet the customers’ requirements, all measuring devices and instruments are calibrated in accordance with the accepted standards, including:

  • ASTM E4,
  • ASTM E467,
  • ASTM E83,
  • ASTM E1012,
  • ASTM E220,
  • ASTM E574.

The laboratories and staff of the Institute have numerous certificates and diplomas confirming the highest competences.

Fatigue tests – equipment

We have many machines and devices from renowned manufacturers:

  • 11 (eleven) MTS 100 kN fatigue testing machines,
  • 6 (six) INSTRON 100 kN fatigue testing machines,
  • 4 (four) MTS 250 kN fatigue testing machines,
  • 2 (four) MTS 25 kN fatigue testing machines,
  • 6 (six) MTS 50 kN fatigue testing machines.

We offer the ability to create your own complex programs that allow you to simulate the real course of loads of the tested element in an unlimited way. We carry out tests at a constant ambient temperature thanks to specially designed air conditioning installed in the room where the research stands are located. We have our own voltage support system that allows us to continuously conduct long-term tests without the risk of losing test data.

Fatigue tests – standards and certificates

We have obtained the GE S-400 certificate for performing tests in the field of high and low cycle fatigue tests (HCF and LCF), which is a confirmation of meeting the high expectations of our Customers in this area. The certificate received is a supplement to the confirmation of competence in the field of static tensile tests at room temperature and elevated temperatures, as well as creep tests.

We also have a high potential in the field of fatigue testing of composite materials. The tests are performed using state-of-art testing equipment in accordance with international standards. We have PCA and NADCAP accreditation in the field of testing non-metallic materials. Fatigue tests of composite materials are performed at temperatures from -130°C to 315°C, with a maximum load of 250 kN.

Physicochemical tests

We have the necessary knowledge, experience and appropriate technical potential to perform tests of the structure of materials and the surface of materials with determination of chemical composition, fractographic tests, as well as measurements of material properties.

Physical and chemical tests – scope of services:

  • metallography;
  • fractography with the use a scanning microscope (fracture sites, material homogeneity control);
  • determination of the chemical composition using the EDS method (identification of materials, impurities and assessment of the concentration of elements on the surface of the sample);
  • microstructure analysis – metallographic and optical microscopy;
  • surface analysis;
  • roughness.

Microscopy is used to obtain information on:

  • shape,
  • sizes of the analyzed samples and objects,
  • elemental composition, crystallographic structure,
  • mechanical properties,
  • electric or magnetic.

We perform microscopic tests using the following equipment:

  • Keyence VHX 6000 digital microscope;
  • metallographic microscope Neophot 2, magnification range 50x through 2000x;
  • Zeiss EVO 25 MA SEM microscope with BSD and SE detectors.

The scope of tests in our offer:

  • analysis, processing of digital images, measurements of geometrical quantities;
  • three-dimensional imaging of the surface topography of samples;
  • in the magnification range of 100–500x the possibility of observation in a bright and polarized light field;
  • 100x through 1000x: DIC dark field observation capability;
  • observation at magnification from 20x through to 5000x (digital zoom).

Fractography

We perform tests and analyzes of the surface of fractures of solids, enabling us to determine the causes of cracks in the material.

Fractography – testing capabilities

We perform fracture surface testing for both metallic and non-metallic samples.

The range of tests we offer:

  • evaluation of grain size, surface roughness, porosity, coating thickness, particle distribution of material homogeneity, non-metallic inclusions, diffusion of elements;
  • fatigue analysis:
    • localization of impurities, microcracks, crack sources;
    • assessment of fatigue failure, determination of the type of fractures.

Fractography – equipment:

  • Zeiss EVO 25 MA scanning electron microscope with BSD and SE detectors,
  • Q150R samples preparation system.

Metallography

We are engaged in microscopic testing to determine the type, morphology, distribution or dimensions of the components of the structure being examined.

Metallography – testing capabilities

The range of tests we offer:

  • determination of grain size and non-metallic inclusions,
  • determining the volume proportion of phases,
  • defining the thickness of coatings,
  • preparation of metallographic specimens.

Metallography – equipment:

  • metallographic microscope Neophot 2, magnification range 50x through 2000x;
  • cutting machine (with manual cutting function and automatic with cooling system);
  • press for mounting the test specimen with a maximum diameter of 40 mm;
  • grinding and polishing machine with the capability of preparing up to 6 samples at the same time.

We have a testing facility that uses the phenomenon of X-ray diffraction to measure the stress, texture and phase composition of the material.

Measurements are made both in relation to samples with given parameters and real construction elements, such as:

  • engine valves,
  • turbine blades,
  • gear wheels,
  • other items produced by traditional and additive methods.

Extensive laboratory equipment enables the implementation of measurements for intricate geometries and complex issues.

X-ray diffractometer

A diffractometer is a measuring instrument designed to analyze the structure of crystalline substances, performed on the basis of their diffraction images. It registers the directions (flare angles) and the intensity of the diffracted radiation beams. The most commonly used instruments of this type are X-ray diffractometers.

X-ray diffractometer – research capabilities

EMPYREAN PANALYTICAL X-RAY DIFRACTOMETER

Scope of tests we offer:

  • quantitative and qualitative testing of the phase composition, monitoring the degree of contamination of the material;
  • measurement and analysis of crystallographic texture;
  • measurement and analysis of the residual stress level on the surface and determination of the stress gradient into the sample/component;
  • measurement of grain size and microstresses;
  • measurements for thin layers of a given thickness;
  • particle and pore size analysis (using the low angle method);
  • determination of layer thickness and roughness (X-ray reflectometry).

X-ray diffractometer – equipment

X-ray tubes:

  • Cu – phase identification, quantitative analysis, high resolution diffraction;
  • Mn – residual stress analysis for austenitic steels, nickel, copper and cobalt alloys;
  • Cr – analysis of residual stresses for steel, aluminum alloys, materials with significant unit cell sizes.

Detectors:

  • proportional detector – more accurate, consisting of a cylindrical chamber filled with a mixture of xenon and methane;
  • PIXcel 1D – faster X-ray detection system based on Medipix3 semiconductor technology.

Accessories allowing measuring of stress, texture and phase analysis of samples with irregular shapes, including printed components:

  • parallel beam mirror for radiation of Cu and Cr lamps;
  • parallel beam lenses – focusing the entire power of the X-ray beam at a specific point without loss of intensity while forming a quasi-parallel beam;
  • 5-axis table – automated rotation around two axes (χ, φ) and movement in three directions (x, y, z).

Portable diffractometer

A diffractometer is a measuring instrument designed to analyze the structure of crystalline substances, performed on the basis of their diffraction images. It registers the directions (flare angles) and the intensity of the diffracted radiation beams. The most commonly used devices of this type are X-ray diffractometers.

Portable diffractometer – testing capabilities

PORTABLE DIFRACTOMETER XSTRESS 3000 G2R (STRESSTECH)

Scope of tests we offer:

  • fast analysis of residual stresses for samples with complex shapes and large sizes;
  • portable device – the possibility of measurements both in the laboratory and in the field;
  • possible measurement of actual stresses applied to determine the characteristics of a specific material;
  • automated X-Y table – measurement of stress distribution on the sample surface, automatic measurement of many samples;
  • collimators (measuring spot size) – from 0.5 mm to 5 mm.

Portable diffractometer – equipment

X-ray tubes:

  • Mn – measurement of residual stresses for austenitic steels, nickel, copper and cobalt alloys;
  • Cr – especially dedicated to the measurement of residual stresses in ferritic steels and aluminum alloys;
  • Ti – analysis of residual stresses in titanium alloys;
  • V – others, complementary applications.

Detectors:

  • two symmetrically arranged NMOS position-sensitive detectors with a range of 15°.

Electropolishing

The electropolishing process makes it possible to obtain a smooth surface of the material, protecting it against corrosion.

Electropolishing – testing capabilities

The Kristall 650 portable device we use is an electrolytic polishing and etching tool that guarantees control of all electropolishing parameters. It is perfect for places where traditional sampling is not feasible.

Electropolishing – equipment

  • portable electropolishing device – Kristall 650;
  • Mitutoyo tripod with granite plate and digital depth gauge with a resolution of 0.0005 mm.

Validation and reference samples

vTesting capabilities:

  • tensile machine designed for validation measurements of diffraction stress measurement;
  • certified annealed samples (Fe-Aust, Al, Ti, Mg, Inconel 718, Cu, Fe-Ferr, Ni);
  • certified sample with known stress level;
  • standard reference samples (certified by the National Institute of Standards and Technology, NIST);
  • lanthanum hexaboride 660c powder (pattern of diffraction line position and shape);
  • silicon powder 640e (pattern of the position and shape of the diffraction line);
  • corundum plate 1976b (position and intensity pattern of the diffraction line).

Examples of conducted experiments:

  • measurement of stress gradient around rivets in sheets made of aluminum alloy (as part of a project to improve the fatigue life of rivet joints);
  • measurements of residual stresses at the bottom of the screw thread made of titanium alloy;
  • measurement of residual stresses on samples made of Inconel 718/steel, dedicated to fatigue tests;
  • measurement of residual stresses at the bottom of a notch in a gear wheel made of low-carbon AMS 6265 steel;
  • testing of the impact of markings made with the use of a laser and vibropen on the level of stress in samples made of nickel alloy;
  • measurement of residual stresses on specimens dedicated for erosion failure testing for 17-4PH stainless steel;
  • measurement of residual stresses on a wheel made of 13-8PH steel;
  • phase analysis and texture measurement for thin layers made of Ni/SiC composite;
  • phase analysis and stress measurement on printed samples made from Inconel 718 CoCr alloys and SS316L;
  • measurement of stress distribution for the “heat shield” element made of nickel alloy;
  • phase composition measurement for aircraft engine sludge;
  • measurement of stresses in depth for aircraft engine blade locks made of Inconel 718 alloy;
  • stress measurement near cracks for aircraft engine blades made of titanium alloy;
  • measurement of stresses on the surface of valves made of steel after padding and nitriding, together with a prior phase analysis;
  • stress measurement around joints made using the RFSSW method for 7075 aluminum alloy sheets.

Analysis of the chemical composition of EDX

Analysis of the chemical composition is a tool used in material testing, enabling surface and volume identification of the chemical elements of the tested material.

Analysis of the chemical composition of EDX – testing capabilities

Scope of tests we offer:

  • analysis of the chemical composition of the sample,
  • material identification,
  • identification of impurities,
  • determination of the relative concentration of elements on the surface of the sample.

We test metals as well as ceramics, glass, polymers and concrete.

Analysis of the chemical composition of EDX – equipment

  • Bruker EDX XFlash 5010 detector (energy resolution 125 eV).

Thermal analysis

Thermal analysis is a set of testing methods that provide information on changes in chemical and physical properties that occur during heating/cooling of a substance. These methods make it possible to determine such thermal parameters as, for example:

  • glass (transition) temperature,
  • melting point,
  • breakdown temperature,
  • heat of fusion,
  • specific heat,
  • polymorphic changes.

Thermal analysis – testing capabilities

Scope of tests we offer:

  • thermal analysis:
    • DMA,
    • DSC,
    • TGA,
    • FTIR;
  • determination of the glass (transition) temperature according to the following standards:
    • ASTM E1640,
    • ASTM D7028;
  • melting enthalpy and crystallization of the polymers:
    • ASTM D3418;
  • thermal expansion testing according to ASTM E228 standard,
  • thermogravimetric analysis according to ASTM E1131 standard.

Thermal analysis – equipment

  • dynamic thermomechanical analyzer Perkin Elmer DMA 8000:
    • determination of the glass (transition) temperature,
    • temperature range: -180°C ÷ +400°C,
    • capability to perform measurements of mechanical and viscoelastic properties of such materials as:
      • thermoplastics,
      • thermosetting plastics,
      • elastomers,
      • ceramics,
      • metals;
  • differential scanning calorimetry (DSC):
    • phase transition analysis,
    • determination of specific heat,
    • glass (transition) temperature,
    • melting point,
    • crystallization temperature,
    • testing of resin cross-linking processes,
    • the subjects of the test are:
      • plastics,
      • composites,
      • resins,
      • organic and inorganic compounds,
      • minerals,
      • samples of natural origin;
  • TGA thermogravimetric analysis:
    • identification of the tested material,
    • analysis of its composition,
    • determination of filler content and other additives,
    • determination of thermal stability of such materials as:
      • plastics,
      • composites,
      • organic and inorganic compounds,
      • minerals,
      • samples of natural origin;
  • spectrophotometry Fourier Transform Infra Red (FTIR) – determining the chemical composition of the tested material;
  • Anter UNITHERMTM 1000 dilatometer – thermal expansion test, temperature range: -196°C ÷ +1100°C.

Surface roughness tests

Surface roughness expresses the unevenness of the surface of a solid resulting from the nature of processing and the tool used, the magnitude of which depends on the type of material and the preparation used.

Surface roughness tests – testing capabilities

Surface roughness tests we perform using the Mitutoyo Surftest SJ-301 surface roughness tester with the following parameters:

  • feed unit: X axis: measuring range: 12.5 mm;
  • measuring speed: 0.25 + 0.5 mm/s;
  • detector range: 350 µm;
  • measurement method: contact;
  • pressing force: 0.75 mN;
  • measuring tip: diamond (60⁰/2 µmR);
  • parameters:
    • Ra,
    • Ry,
    • Rz.

Chemical tests

Expanded in 2023, the Chemical Research Laboratory for space applications enables a global-scale investigation of physico-chemical properties and chemical compatibility of propellant materials.

Łukasiewicz – Institute of Aviation is a leading research and development unit in Poland and worldwide in the field of ecological rocket propulsion. Its primary areas of interest and specialization lie in environmentally friendly liquid and hybrid propulsion systems based on over 98% hydrogen peroxide, as well as innovative hypergolic fuels.

The in-house capabilities of production of hydrogen peroxide with concentrations exceeding 98% are based on a patented method, providing independence in preparations for testing engines and other components utilizing HTP.

The chemical laboratory – tasks

  • Research on fuels for new liquid, hybrid, and gel propulsion systems.
  • Research on fuels hypergolic with hydrogen peroxide (production, long-term storage, passivation, and compatibility studies).
  • Research on chemical durability of fuels containing catalytic and/or energetic additives.
  • Investigation of physicochemical parameters useful for propulsion applications.
  • Development of advanced low-smoke solid rocket propellant materials.
  • Research on high-performance environmentally friendly fuels and oxidizers of a new generation.
  • Development of catalysts for single-component propellant applications.
  • Research on the chemical compatibility of different structural materials with working fluids.
  • Development of fuel compositions that spontaneously react with hydrogen peroxide (hypergolic).

The chemical laboratory – equipment

  • Nicolet iS50 FT-IR spectrometer with built-in ATR.
  • Vhx 7000 digital microscope.
  • laboratory muffle furnace type FCF 22 SHM.
  • vibratory sieve shaker AS Control.
  • planetary ball mill PM 100.
  • stand for casting solid rocket propellant materials.

Prototypes of propellant materials obtained through casting process and after thermal conditioning must undergo testing to meet specified parameters, including ballistic, mechanical, thermochemical properties, and safety requirements. Only with a ready and properly characterized propellant material can full thruster tests be conducted, which are performed on site on vacuum or atmospheric test stands. Consolidating the research facilities in one place enables comprehensive research and development of solid propellant materials while increasing their safety.

Electrochemical testing capabilities

We offer tests in the field of electrochemical processes and corrosion resistance using electrochemical methods according to the following standards PN – EN, ISO, ASTM or under individually selected conditions for the following sectors:

  • Aerospace and automotive industry,
  • Space industry,
  • Medical industry, e.g. bio-implants, surgical instruments, stents etc.
  • Coated and uncoated metal structures.

Examples of research possibilities:

  • Corrosion resistance testing of uncoated and coated metals by electrochemical impedance spectroscopy (EIS) according to the standard PN-EN ISO 16773-2.
  • Corrosion resistance testing of stents and surgical instruments according to ISO 10993-15.
  • Galvanic corrosion susceptibility testing of implant materials according to ASTM G71-81. Also, other materials.
  • Cathodic disbonding testing of epoxy and polyester coatings according to ASTM G8-96.
  • Corrosion testing of metallic grounding components inserted in the moist soil, by means of the polarization resistance method according to ASTM G59 standard.

We also provide technical advice, expertise and bespoke services in this area.

Non-destructive tests

We have many years of experience in the implementation of non-destructive tests, enabling the assessment of the material condition, necessary to ensure the reliability of the structure. The idea of non-destructive testing is to detect and determine the configuration, distribution, and size of defects arising in the production process and during operation, both in relation to complete structures and their components, as well as semi-finished products.

Typical examples of detected defects are:

  • fatigue cracks,
  • corrosion,
  • blisters,
  • inclusions,
  • leaks,
  • welding defects.

The personnel performing non-destructive testing is qualified and certified in accordance with PN-EN ISO 9712 “Non-destructive testing – Qualification and certification of non-destructive testing personnel”.

The scope of our offer includes the following non-destructive testing methods:

  • eddy current tests (ET),
  • penetration tests (PT),
  • ultrasonic tests (UT),
  • magnetic-particle tests (MT),
  • visual tests (VT),
  • X-ray computed tomography (RT/CT).

Non-destructive testing – certificates

  • accreditation AB 792 – PN-EN ISO/IEC 17025:2018,
  • personnel certificates in the field of non-destructive testing.

We develop methodology and tests at various stages of the production process, in industrial, field and laboratory conditions. We perform ad hoc tests and non-standard non-destructive condition diagnostics, including preparation of instructions and technical descriptions.

The visual method, which is the basis for the implementation of other non-destructive tests, consists in the direct detection and assessment of discontinuities on the surface of the tested object.

Visual tests can be divided into direct, enabling the analysis of directly accessible surfaces with the unaided eye or using microscopes, and indirect – optical, allowing for the verification of directly inaccessible surfaces using devices such as endoscopes, videoscopes or borescopes.

This method enables the detection of large surface discontinuities and shape defects of the tested object.

Visual method – testing capabilities

  • surface defects detection;
  • types of detected discontinuities: fatigue cracks, heat treatment cracks, operational damage, welded joints;
  • endoscopy and borescopy – detecting defects in an inaccessible place.

Visual method – equipment:

  • Olympus fiberscope system,
  • Everest borescope system.

The oldest method of non-destructive testing used to verify both metallic and non-metallic materials. Penetration testing is based on the capillary phenomenon – penetration of the penetrant into very narrow, also hard-to-reach spaces, also against the law of gravity. A very effective and universal method useful for detecting surface defects in materials.

Penetration method – testing capabilities

  • Testing of surface discontinuities of non-porous materials (metallic and non-metallic):
    • steel and its alloys,
    • non-ferrous metals,
    • ceramics,
    • glasses,
    • plastics.
  • Types of detected discontinuities:
    • cracks (e.g. fatigue, grinding),
    • porosity,
    • scratches,
    • delamination,
    • lapping,
    • overlaps,
    • corrosion (point, surface),
    • leaks.

Penetration method – equipment

  • Magnaflux penetration kits,
  • UV and white light illuminators,
  • patterns,
  • UV light and intensity meters.

Based on the phenomenon of electromagnetic induction, it consists in inducing a current in a conductive material as a result of the alternating magnetic field acting on the material. The analysis of the value of changes in the electromagnetic field, the amplitude of the output signal or the amplitude of the phase shift makes it possible to assess the condition of the tested material. The test allows to detect surface discontinuities and subsurface defects, also for elements with large dimensions and complex geometric shapes.

Eddy current method – testing capabilities

  • testing of materials that demonstrate electrical conductivity;
  • detection of surface and subsurface defects – cracks (fatigue, hardening, grinding), inclusions, corrosion, coating thickness measurement, comparative structural tests.

Eddy current method – equipment:

  • GE Inspection Technologies Phasec 3D eddy current flaw detector with sets of specialized probes;
  • Patterns of defects, conductivity, degree of corrosion.

The method relies on the excitation of a magnetic field in the tested object and the use of a fine-grained ferromagnetic powder to detect magnetic scattering fields arising on the surface of the tested element, in the areas of surface and subsurface material discontinuities.

Magnetic powder method – testing capabilities

  • detection of surface and subsurface defects (inclusions, pores, blisters) of all ferromagnetic materials;
  • basic detection of surface, thermal and mechanical defects – grinding cracks, hardening cracks, etc.

Magnetic powder method – equipment

  • yoke defectoscopes Magnaflux, Parker;
  • Magnaflux fluorescent and black suspensions;
  • UV and white light illuminators;
  • magnetic indicators;
  • standards.

The method uses the energy of high-frequency sound waves. The waves introduced into the tested object are reflected by material discontinuities, deflection and scattering at their edges. The test enables the detection of defects in the entire volume of the verified material – the location of internal, surface and subsurface discontinuities, as well as the determination of material properties.

Ultrasonic method – testing capabilities

  • detecting defects in the internal structure and determining their location, configuration and size, such as:
    • cracks,
    • blisters,
    • inclusions,
    • a number of other discontinuities in metal,
    • non-metallic and composite materials,
    • welds;
  • material thickness measurements,
  • studies of remote places,
  • invisible surfaces,
  • sections,
  • determining material properties.

Ultrasonic method – equipment

  • GE Inspection Technologies Phasor XS flaw detector with Phased Array,
  • specialized heads and standards.

X-ray computed tomography (2D/3D) consists in x-raying of the tested element with high-energy ionizing radiation (X or gamma), emitted by an X-ray tube or a radioactive element. The detection of material discontinuities is based on the phenomenon of changing the intensity of radiation reaching the detector after passing through the verified object. Radiography is one of the most effective non-destructive testing methods for detecting and locating internal imperfections in any material.

X-ray method – testing capabilities

  • detection of internal structure defects in any materials,
  • volumetric studies of objects,
  • dimensioning of internal elements,
  • volumetric testing of the correctness of assembly,
  • welds testing.

X-ray method – equipment

X-ray tube 240 kV/320 W

  • detail detectability: 1 μm,
  • maximum resolution: 2 μm,
  • maximum object size (height x diameter) – 410 mm x 300 mm,
  • maximum object weight: 10 kg,

Environmental tests

As part of the accreditation for compliance with the requirements of the PN–EN ISO/IEC 17025:2005 standard, we conduct tests in the field of resistance and resistance to mechanical and climatic exposure, as well as functional tests of products.

Environmental tests – scope of the tests offered

  • tests resistance and strength tests of sinusoidal and random vibration,
  • tests resistance and strength tests for mechanical shocks,
  • tests of resistance and vibration strength in combination with temperature and/or relative humidity,
  • tests of resistance to low and high temperatures,
  • tests of resistance to cyclic temperature changes,
  • tests of resistance to changes in temperature and atmospheric pressure,
  • tests of resistance to condensation deposits (frost and dew),
  • tests of resistance to increased humidity,
  • tests of resistance to dust,
  • tests of resistance to corrosion (salt spray),
  • tests of resistance to precipitation,
  • solar radiation resistance tests,
  • tests in vacuum.

The purpose of carrying out climatic tests is to determine the behavior of materials and structures in given environmental conditions. Simulation of various atmospheric factors allows for verification of the legitimacy of using the tested objects in a specific environment.

Climatic tests – testing capabilities

We have a wide range of high-quality equipment that allows us to conduct various climatic tests. We provide qualification in the area of high and low pressures and a wide range of temperatures, using pressure, temperature, temperature-pressure, gas and water tests, as well as leak tests using a helium detector. We have expanded our offer to include the implementation of tests in a vacuum chamber – the first such device used in Poland. The tests are carried out by qualified personnel with competence and specialized knowledge.

Scope of tests we offer:

  • tests of resistance to low and high temperatures,
  • tests of resistance to cyclic temperature changes,
  • tests of resistance to changes in temperature and atmospheric pressure,
  • tests of resistance to condensation deposits (frost and dew),
  • tests of resistance to increased humidity,
  • tests of resistance to dust,
  • tests of resistance to corrosion (salt spray),
  • tests of resistance to precipitation,
  • solar radiation resistance tests,
  • tests in vacuum.

Climatic tests – equipment

THERMO-BARO CHAMBER CLIMAS TYPE 1000 FCV 70/1 WITH SPIRALE VS CONTROLLER

  • working space dimensions: 1000 x 1000 x 1000 mm (1000 l);
  • temperature range: -70°C ÷ +180°C;
  • pressure range:
    • from atmospheric to 10 hPa – without temperature control,
    • from atmospheric to 50 hPa – with temperature control,
    • from atmospheric to 1070 hPa

CLIMATIC CHAMBER CLIMATS 4000 H 70/4G WITH SPIRALE 3 CONTROLLER

  • working space dimensions: 2000 x 1900 x 1060mm (4000 l);
  • temperature range: -70°C ÷ +180°C;
  • humidity range: 20% ÷ 95%.

CLIMATIC CHAMBER CLIMATS EXCAL 7728–HE WITH SPIRALE 3 CONTROLLER

  • working space dimensions: 900 x 950 x 900mm (770 l);
  • temperature range: -90°C ÷ +200°C;
  • speed of temperature change: 17°C/min in the temperature range from -55°C to +180°C;
  • humidity range: 20% ÷ 95%.

CLIMATIC CHAMBERS

  • working space dimensions: 2500 x 2500 x 2500 mm;
  • temperature range: -100⁰C ÷ +260⁰C;
  • temperature change rate: 2⁰C/min.

TEST POOL

  • working space dimensions: 4500 x 4500 x 4500 mm;
  • hydraulic tests: ~2900 bar;
  • gas tests: ~1720 bar.

TEST BED FOR RAPID PRESSURE CHANGES (DECOMPRESSION)

  • chamber dimensions: 770 x 800 x 800mm (490 l);
  • pressure changes from 746.7 hPa to a pressure in the range of 467 to 90 hPa;
  • pressure change time no more than 15 ms.

SALT CHAMBER TYPE SF/CCT/VH WITH EUROTHERM CONTROLLER

  • working space dimensions: 850 x 2000 x 1000mm (1700 l);
  • temperature range: from ambient temperature to +60°C (with humidity) and up to +70°C (without humidity);
  • tests in accordance with the standards: MIL STD-810E, ISO 6270-2, DIN 50.02, ASTM 13117;
  • humidity range:
    • from 50% to 95% at 20°C,
    • from 30% to 95% at 30°C,
    • from 15% to 95% at 60°C.

RAIN CHAMBER TYPE SWT 600/800 WITH SIMPATI CONTROLLER

  • working space dimensions: 1810 x 1800 x 1800mm (5800 l);
  • turntable diameter: 600 mm;
  • the capability to perform tests in accordance with: IPX1, IPX2, IPX3, IPX4, IPX5, IPX6, IPX6K.

SUNEVENT SUN/1000 SOLAR RADIATION SIMULATION CHAMBER WITH SIMPATI CONTROLLER

  • working space dimensions: 1000 x 1000 x 1000 mm (1000 l);
  • irradiation module:
    • metal halide lamp: 2500 W,
    • radiation intensity: 400-1125 W/m²,
    • light range: 280-3000 nm.

DUST CHAMBER ST 2000U WITH SIMPATI CONTROLLER

  • working space dimensions: 1000 x 1900 x 950mm (1800 l);
  • dust capacity: 5 kg of dry talc dust;
  • the capability perform tests at temperature up to 55°C and in accordance with DIN EN 60529.

N2 GAS GENERATION SYSTEM

  • liquid nitrogen tank 20 tons,
  • evaporator from the pumps,
  • bundles of 700 l cylinders gas pressure 200 bar.

HPU HYDRAULIC POWER SUPPLY CONTROLLED FROM PLC

  • capacities:

5 kpsi (~350 bar) – oil units,
20 kpsi (~1400 bar) – water units.

HELIUM DETECTOR

We perform leak detection services using a helium detection device. Localization and measurement of the size of infiltration in the objects under test can be done in two ways:

  • inside the object under test, a positive pressure of helium is generated, and the leak is searched for externally using a sniffer;
  • a vacuum is generated inside the object, while the object itself is blown with helium from the outside;
  • Two modes of testing: vacuum and sniffing.

HIGH PRESSURE GENERATORS

  • gas N2 to 25 kpsi (~1720 bar),
  • liquids up to 42 kpsi (~2900 bar).

MEASURING DEVICES – LASER TRACKER

  • Precise 3D measurements.

HYDRAULIC PRESS (CRUSHER) CONTROLLED VIA PLC, WORKING IN TWO DIRECTIONS

  • crushing force: 1.5 M lbs (push) 680 tons,
  • stretching force: 0.1 M lbs (pull) 45 tons.

MULTI-CHANNEL DATA REGISTRATION SYSTEMS (DAS)

  • calibration and acquisition.

Tests of resistance and endurance to mechanical stress make it possible to identify, analyze and evaluate the risks arising from the effects of vibrations or shocks on the tested object, allowing to determine the degree of resistance of the object and its strength.

Mechanical tests – testing capabilities

We perform tests to determine the resistance and strength of materials and structure for vibrations and mechanical shocks.

We have a wide range of high-quality devices designed to perform the following mechanical tests:

  • tests resistance and strength tests of sinusoidal and random vibration,
  • tests resistance and strength tests for mechanical shocks,
  • tests of resistance and vibration strength in combination with temperature and/or relative humidity,
  • testing of rotating components in a vacuum.

The tests are carried out by qualified personnel with competence and specialized knowledge.

Mechanical tests – equipment

IMV I250/SA4M-CE SHAKER WITH MEDALLION II CONTROLLER

  • oscillation frequency 5 – 2500 Hz;
  • maximum displacement amplitude: 50 mm;
  • maximum force: 40 kN;
  • maximum acceleration:
    • for sinusoidal vibration: 500 m/s²,
    • for random vibration 140 m/s²,
    • for shocks: 800 m/s²,
  • additional equipment:
    • sliding table with dimensions: 750 x 750 mm,
    • head-expander with dimensions: 700 x 700 mm,
    • head-expander with diameter: 610 mm;

CLIMATIC CHAMBER (FOR VIBRATION TESTS AT SPECIFIC TEMPERATURES) TYPE CLIMATS 1200 H 70/5 WITH SPIRALE 3 CONTROLLER

  • working space dimensions: 1000 x 1100 x 1100mm (1200 l);
  • temperature range: -70°C ÷ +180°C;
  • speed of temperature change: 5°C/min;
  • humidity range: 20% ÷ 95%.

MOBILE CLEANROOM MODEL SC-35/25/29 with dimensions: 3.5 x 3.0 x 2.6 m;

  • antistatic transparent PVC strip curtains;
  • HEPA filter – ISO7;
  • automatic airflow: 0.45 m/s;
  • can be used for vibration tests in clean air.

VACUUM CHAMBER

  • working length: 9.65 m;
  • diameter: 5.5 m;
  • total volume: 265 m3;
  • total mass: 177 tons;
  • speeds: up to 12,000 rpm;
  • performance of tests of the rotating elements.

Microgravity is a state of space in which gravitational acceleration is significantly reduced or completely eliminated, while the gravitational force itself still exists – a so-called state of weightlessness is created.

One method of creating a microgravity environment is suborbital flight aboard a rocket. The rocket, being at a significant altitude, which is not affected by aerodynamic forces and has its propulsion system turned off, experiences free fall, as a result of which the rocket’s payload is subjected to microgravity.

Microgravity aboard suborbital rockets can be used to precisely measure the thermophysical properties of liquid metals or to study the response of living organisms to gravitational stimuli.

Tests in microgravity conditions – testing capabilities

With the ILR-33 BURSZTYN 2K rocket, a cost-effective, scalable and environmentally friendly design, we have the ability to efficiently experiment in microgravity and probe the atmosphere. The ILR-33 BURSZTYN 2K rocket is used during flight as a suborbital test platform, capable of providing up to 150 seconds of microgravity conditions for a 10 kg payload. The payload compartment can be adapted to the Customer’s requirements, providing the best possible test conditions.

Technical parameters of the ILR-33 BURSZTYN 2K rocket

Length4.6 m
Main stage diameter230 mm
Flight ceiling100 km
Maximum speed1300 m/s
Payload weight10 kg
Maximum gravity load14 g
Duration of microgravity (10-3 g, 5 kg)150 s

Auxiliary engines

TypeSolid propellant
Maximum thrust2 x 16 000 N
Working time6 s
Combustion chamberComposite structure

Main engine

TypeHybrid rocket engine
OxidizerHydrogen peroxide (H2O2), concentration 98%+
FuelPolyethylene
Maximum thrust4,000 N
Working time40 s
Combustion chamberComposite structure

Qualification tests of composite materials

We have a high potential in the field of testing composite materials – we perform comprehensive testing of composite materials, also intended for aviation structures. Tests are performed using modern testing equipment in accordance with international standards. We have PCA and NADCAP accreditation in the field of testing non-metallic materials.

We offer the following services:

  • qualification tests of composite materials;
  • component-level damage tolerance assessment;
  • static and fatigue tests, maximum load up to 250 kN;
  • testing at temperatures from -130°C to 315°C;
  • digital image correlation, the use of strain gauges and extensometers;
  • testing using standardized instrumentation as well as designing and manufacturing testing instruments tailored to the individual needs of Customers;
  • impact resistance testing, simulated energy range from 0.59 J to 1800 J;
  • thermal analysis of composite materials DMA, DSC, TGA, FTIR;
  • sample preparation – cutting, grinding, drilling, gluing, conditioning

Testing of material properties:

  • stretching,
  • squeezing,
  • shearing,
  • interlayer shearing,
  • three-point bending,
  • cracking.

Laminates testing:

  • stretching a sample with a hole,
  • squeezing a sample with a hole,
  • squeezing after impact.

Knuckle joint connections tests:

  • stretching,
  • plucking.

Testing of adhesives:

  • shear strength,
  • peel strength.

Testing of fillers and sandwich structures:

  • squeezing,
  • filler shear,
  • tearing the spacer,
  • beam bending.

Impact tests:

  • impact strength,
  • impact resistance.

Physical and chemical tests:

  • thermal analysis of composite materials:
    • DMA,
    • DSC,
    • TGA,
    • FTIR;
  • determination of the glass (transition) temperature according to the following standards:
    • ASTM E1640,
    • ASTM D7028;
  • enthalpy of melting and crystallization of polymers according to ASTM D3418;
  • thermal expansion test according to ASTM E228 standard;
  • thermogravimetric analysis according to ASTM E1131 standard;
  • testing of untoughened pre-impregnate (gel time, resin flow, resin content);
  • fiber content test according to ASTM D3171 standard.

Equipment:

  • dynamic thermomechanical analyzer Perkin Elmer DMA 8000:
    • determination of the glass (transition) temperature
    • temperature range: -180°C ÷ 400°C,
    • the ability to measure mechanical and viscoelastic properties;
  • differential scanning calorimetry DSC:
    • phase transition analysis;
    • determination of specific heat;
    • glass (transition) temperature;
    • melting;
    • crystallization;
    • study of resin cross-linking processes;
    • the subjects of the test are:
      • plastics.
      • composites
      • resins
      • organic and inorganic compounds,
      • minerals or samples of natural origin.
  • TGA thermogravimetric analysis:
    • identification of the tested material,
    • analysis of its composition,
    • determination of filler content and other additives,
    • determination of thermal stability of such materials as:
      • plastics
      • composites
      • organic and inorganic compounds,
      • minerals
      • samples of natural origin;
  • FTIR spectrophotometry:
    • determining the chemical composition of the tested material;
  • Anter UNITHERMTM 1000 dilatometer:
    • thermal expansion test,
    • temperature range: -196°C ÷ 1100°C.

Non-destructive testing and quality control processes

All technological works are subject to quality control. This process includes verification of documentation and materials, supervision over the production cycle and inspection of the product. The scope of quality control is adjusted each time to the specificity of the work performed.

The scope of our services:

  • ultrasonic testing of composite structures using the phased array technique (C-scan), conventional;
  • low-frequency testing of composite structures using bond testing (C-scan), tap testing (woodpecker, hammer);
  • thermographic studies of composite structures (active thermography);
  • visual inspection of composite structures;
  • microscopic measurement of porosity;
  • comprehensive development of methodologies for non-destructive testing of composite structures;
  • calibration plates design;
  • detection of defects such as delaminations, cracks, porosity, foreign bodies.

Equipment:

  • Olympus OmniScan MX Flaw Detector:
    • detection of defects in monolithic composite samples,
    • main unit with two test modules Phased Array 128:32 I UT 2C;
  • Olympus BondMaster:
    • detection of defects in sandwich structures,
    • pitch-catch method,
    • resonant method,
    • acoustic impedance method;
  • KIMLA BPF2070 CNC plotter – working area: 7 x 2 x 0.5 m;
  • furnace designed for hardening and post-hardening of composite structures, dimensions:
    • 10 x 2.4 x 2 m,
    • maximum operating temperature 200°C;
  • precise furnace for hardening test pieces;
  • climatic chamber:
    • capacity: 280 l,
    • dimensions: 720 x 690 x 560 mm,
    • temperature range:  from -50°C to + 180°C.
    • temperature range including humidity: from 10°C to + 95°C.
    • relative humidity range: from 10% to 98%;
  • universal milling machine:
    • work area: 1320 x 320 mm,
    • position reading in 3 axes,
    • feed: 20 – 360 mm/min,
    • speed of rotation: 58 – 1800 rpm;
  • surface grinder:
    • work area: 250 x 600 mm,
    • max grinding length: 600 mm;
    • minimum feed: 0.001,
    • maximum feed: 0.06,
    • speed of a spindle: 2900 rpm.

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