Attachment 1 - Specifications.pdf

NRL Code 6300 Advanced Materials Test System Specifications

Background: The Advanced Materials Test (ATM) system consists of a state-of-the-art, computer-controlled screw-drive load-frame with environment control, advanced measurement instrumentation, and a variety of fixtures to connect with material test samples. The proposed system will be used for characterizing load-deformation behavior and measuring critical material properties (elastic moduli, stiffness, strength, elongation, failure loads, etc.) of relevant materials including: structural and multifunctional composites, metals, polymers, elastomers, ceramics, bio-materials, etc. as well as structural components and prototypes. The vast majority of materials (mechanical) testing at NRL involves “non-standard” research experimentation involving elaborate test setups and complex measurements, and unique and diverse:

materials/components, specimen shapes/sizes, test conditions (temperatures, load-time control, etc.), and parameter measurements (2D strain-fields).

General Specifications: The system shall include: load frame (screw-drive; 300 kN load capacity); load-train alignment system; environmental chamber for specimen temperature control (-80 to 350 deg C); non-contact video strain instrument with DIC capability; load-cells and clip-on extensometers and instrumentation; and specimen fixtures for tension, compression, and flexure testing. Software for automated test control, data acquisition, and test analysis. The software must be seamlessly integrated with the environmental chamber and video strain systems for control and synchronized data acquisition from each of these sub-systems.

DETAILED SPECIFICATIONS (MINIMUM):

MATERIALS TEST SYSTEM:

1. Screw-driven load frame with 300 kN load capacity:

• 300 kN load cell. Tension/compression with self-identification, electrical calibration, and necessary adapters to connect to load-frame and test fixtures.

• Crosshead travel of 1800 mm.

• Horizontal test space between columns of 900 mm.

• T-Slot table base for test fixture and specimen mounting.

• Crosshead displacement speed range from 0.0001 to 508 mm/min at zero load.

• Crosshead displacement speed accuracy of +/- 0.1% of the test speed setting.

• Maximum crosshead displacement speed of 254 mm/min at the maximum 300 kN force.

• Maximum force of 125 kN at the maximum crosshead displacement speed.

2. Integrated digital closed-loop control and data acquisition (DAQ) electronics including sensing-control channels for load, crosshead extension, video-strain, extensometers, etc.

• Data acquisition resolution of 19-bit.

• 2.5 kHz DAQ rate, simultaneous on all channels (load, displacement, strain, etc.).

• Force measurement accuracy of 0.5% down to 1/1000 load cell capacity.

• Position control resolution: 3.5 µm.

• Displacement accuracy of +/- 0.01 mm or 0.5% of reading.

• Closed-loop test control capability using any other conditioned signal (#5).

• All required electrical cabling.

3. Hardware and software for test control and data acquisition.

• Computer and related hardware to include:

Attachment 1. N00173-22-Q-SP20

i. Computer (Windows 10, 64-bit) with 21 inch flat industrial-quality touch monitor.

ii. 2 Ethernet ports, 6 USB ports, and wireless network adapter.

iii. Integration with a remote test-control handset, added data channels (#5), video strain system (#7), and the environmental chamber (#8).

iv. Test control panel (monitor) to provide: results display, start, stop and return functions, programmable function keys, test status indicators, variable speed jog, and setting of specimen overload protection.

v. All required mounting hardware and electrical cabling.

SOFTWARE:

• Testing software package to include:

i. Test-method options for experimentally characterizing the mechanical response of plastics, composites, metals, elastomers, biomedical, adhesives, textiles, and components. Capability for tension, compression, flexure, stress-relaxation, creep, peel, tear and friction testing.

ii. Pre-configured test methods for common materials tension, compression, flexure, stress-relaxation, creep, peel, tear and friction testing.

iii. Capability for test control using extension, load or strain signals.

iv. Compatibility, integration, and seamless operations with digital closed-loop control &electronics (#3).

v. Compatibility, integration, and seamless operations with Video Extensometer System (#7).

vi. Compatibility, integration, and seamless operations with Environmental Chamber (#8).

vii. Capability for creating custom test control sequences with a simple, user-friendly interface. Complex cyclic test sequences via waveform building steps (triangles, ramps and holds). Graphic display of test method as it is created. Compatibility with standard Window's commands (e.g., cut, paste, copy, delete, etc.). Independently assign test results to individual test steps. Filtering of graphical display of test results to show only the steps (cycles) of interest.

viii. Libraries/subroutines for typical materials testing parameter calculations (e.g., modulus, ultimate tensile strength) as well as user-defined calculations.

ix. Report generator to create customized report templates linked with test methods and export results saved as HTML, Word or PDF or via email. Customizable raw data and results export capability.

x. Enhanced test control flexibility: ability to change temperatures of the chamber in the middle of a test;

change the data acquisition frequency for each individual segment of the test; change profile parameters between tests; and specimen overload protection capability.

xi. Video Recording/Playback for creating a video record of test and specimen failure using an “user-supplied” USB video recording device. Post-test replay with cursor selection of points of interest.

ACCESSORIES:

1. Load cells for above load-frame:

• 100kN Load Cell. Tension/compression with self-identification, electrical calibration, and necessary adapters to connect to load-frame and test fixtures.

• 30kN Load Cell. Tension/compression with self-identification, electrical calibration, and necessary adapters to connect to load-frame and test fixtures.

• 5kN Load Cell. Tension/compression with self-identification, electrical calibration, and necessary adapters to connect to load-frame and test fixtures.

2. Integrated electrical instrumentation for conditioning strain gages, extensometers, and other measurement devices. To include:

• Eight DAQ channels with signal conditioning for transducer measurements, and DAQ capability of ±10V DC analog inputs. Same resolution and data rates as above (i.e., 19-bit, 2.5 kHz).

• Capability for using additional DAQ channels for closed loop test control.

• Quarter-bridge circuits (350 ohm) for strain-gage measurements. Software-based control of excitation, filtering, amplification.

• Analog Output channels (4), and Digital Input/Output channels (4 of each).

• Remote manual “test event” marker switch.

• All required electrical cabling.

3. Load-train alignment system. Mounted between the load-frame and the 300 kN load cell with necessary hardware, fixtures, software, and electronics. To include:

• Angularity and concentricity adjustments while load is applied to the specimen up to the full load capacity of the system (300 kN applied load).

• Software and electronics for measurement of alignment cell specimen bending with graphical display, test report generation, validation of testing system alignment. Integrated electronics shall provide all needed strain gage conditioning, bridge completion, and data acquisition.

• Compatible with user-provided specimens with eight or twelve (350 ohm) strain gages.

• Strain-gaged alignment cell: flat specimen with gage cross-section sized at approximately 15 x 2 mm and 25 x 2 mm gripped tab dimensions.

• Strain-gaged alignment cell: flat specimen with gage cross-section sized at approximately 12 x 6 mm and 25 x 2 mm gripped tab dimensions.

• Strain-gaged alignment cell: round specimen with gage cross-section diameter of approximately 8 mm and 15 mm of gripped length dimension.

• Onsite instruction covering hardware and software setup, alignment application scenarios, sample setup, specimen parameters, fixture installation and adjustments, report templates.

• Demonstration of alignment testing process with one or more supplied specimens to verify test method and load-train alignment following guidelines detailed in ASTM E1012.

4. Video Extensometer system (hardware and software) for real-time axial and transverse strain extensometry and post-test full-field 2-D strain mapping via Digital Image Correlation (DIC).

All video data (extensometer and DIC) shall be synchronized in time with all the other collected Test System data (e.g., load cell, displacement, DAQ, etc.). To include:

• High-speed video extensometer data acquisition rates (i.e., strain, extension, rotation, etc. data;

this is not the video frame rate) > 450 Hz.

• DIC analysis software for setting-up, analyzing, and determining full-field 2-D strain mapping.

• Video extensometer/DIC software installed and running on the Test System computer (#4); shall be integrated and run seamlessly with all Test System Control/DAQ software functionalities.

• Video extensometer/DIC measurements capable of being with all Test Methods.

• Camera and lens to achieve fov ranges: 100-150 mm; 300-350 mm, 500-600 mm, 800-1000 mm.

• Displacement resolution/accuracy at each fov range:

i. (0.5 µm resolution; ±1 µm or 0.5% reading) with the 100-150 mm fov and the 300-350 mm fov;

ASTM E83 Class B1;

ii. (1.5 µm resolution; ±3 µm or 1% reading) with the 500-600 mm fov; ASTM E83 Class C;

iii. (3 µm resolution; ±9 µm or 1% reading) with the 800-1000 mm fov; ASTM E83 Class C;

• Mounting hardware to connect video system to the load-frame.

• Mounting hardware to connect the video system to the Environmental Chamber window (#8).

• Measurement calibration fixtures, gage marking templates, and marker pens.

• Lighting hardware for specimen illumination for all fov ranges.

• Analog output signals for the real-time axial and transverse video strain measurements.

• DIC analysis software for setting-up, analyzing, and determining full-field 2-D strain mapping.

• All required power and control cabling.

5. Environmental Chamber for test specimen temperature control with roller-support mounting hardware and load-train wedge ports for easy chamber placement and removal from within the load-frame test space.

• Temperature range: -80 to +350°C with LN2 cooling capability.

• Minimum test space inside the chamber: 900 mm height, 400 mm depth and 400 mm width.

• Digital temperature controller.

• Programmable temperature control via Test System software (#4) or manually programming.

• Internal chamber lighting.

• Removable wedge ports for load-train hardware access with instrumentation cut-outs.

• Optical-quality heated glass window for use with video extensometer.

• LN2 Coolant Hose and connections for standard 240 L LN2 dewar.

• All required power and control cabling.

6. 300kN Hydraulic Wedge Grip Set. Upper and lower grips, hardware/adapters for mounting the hydraulic grips to the 300 kN load cell and T-slot base, capability for screw-mounting load cells and fixtures to grip bodies, and a hydraulic pump pressure supply with pressure-connection hoses/fittings and remote grip controls.

• ±300kN load capacity, temperature range: +10 to 60°C.

• Capability and hardware for screw-mounting different load cells and specimen fixtures to the hydraulic grip body (upper and lower grips).

• Specimen insertion via side-entry.

• Fixed faces and moving body during specimen loading.

• Adjustable specimen stops for accurate specimen centering.

• A variety of flat-jaw face sets (4 pieces) with serrated surfaces capable of gripping flat specimens with thicknesses ranging from: 1 to 42 mm.

• A variety of vee-jaw face sets (4 pieces) with serrated surfaces capable of gripping round specimens with diameters ranging from: 5 to 22 mm.

• Stand-alone hydraulic pump for actuating hydraulic grips. User-adjustable gripping pressure.

Capable of continuous pressurization operation. Handset for independent opening, clamping, and locking of the upper and lower grips. Two-stage pressurization (high flow/low pressure, high pressure/low flow). Quiet operation (< 65dB) at full pressure.

7. 150kN Mechanical Wedge Grip Set. Upper and lower grips, mounting hardware, specimen jaw faces, and pull rods for use within the Environmental Chamber.

• 150 kN tensile force capacity, temperature range: -70 to 250°C.

• Specimen insertion via side-entry.

• Fixed faces and moving body during specimen loading.

• Adjustable specimen stops for accurate specimen centering.

• Flat-jaw face set(s) (4 pieces/set) with serrated surfaces capable of gripping flat specimens with thicknesses ranging from: 0 to 12.7 mm.

• A variety of vee-jaw face set(s) (4 pieces/set) with serrated surfaces capable of gripping round specimens with diameters ranging from: 3.5 to 19 mm.

8. 50kN Mechanical Wedge Grip Set. Upper and lower grips, mounting hardware, specimen jaw faces, and pull rods for grips use within the Environmental Chamber.

• 50 kN tensile force capacity, temperature range: -70 to 250°C.

• Specimen insertion via side-entry.

• Fixed faces and moving body during specimen loading.

• Adjustable specimen stops for accurate specimen centering.

• Flat-jaw face set(s) (4 pieces/set) with serrated surfaces capable of gripping flat specimens with thicknesses ranging from: 0 to 12.7 mm.

• Vee-jaw face set(s) (4 pieces/set) with serrated surfaces capable of gripping round specimens with diameters ranging from: 3.2 to 12.5 mm.

9. 10kN Pneumatic Grip Set. Upper and lower grips, mounting hardware, specimen jaw faces, and air-pressure control system.

• 10 kN tensile force capacity, temperature range: -20 to 100°C.

• Flat-jaw face set(s) (4 pieces/set) 25 mm wide with serrated surfaces capable of gripping flat specimens with thicknesses from: 0 to 25 mm.

• Flat-jaw face set(s) (4 pieces/set) with 50 mm or larger width with serrated surfaces capable of gripping flat specimens with thicknesses from: 0 to 25 mm.

• Flat-jaw face set(s) (4 pieces/set) with 25 mm wide rubber-coated surfaces capable of gripping flat specimens with thicknesses from: 0 to 20 mm.

• Flat-jaw face set(s) (4 pieces/set) with 50 mm or larger width with fiberous-composite coated surfaces capable of gripping flat (composite) specimens with thicknesses from: 0 to 20 mm.

• Vee-jaw face set(s) (4 pieces/set) with serrated surfaces capable of gripping round specimens with diameters from: 3 to 6.5 mm.

• Air-pressure control system for grip clamping; compressed air or N2 gas pressure source.

10. 300 kN/150 mm diameter Compression Platens. Upper and lower platens, mounting hardware, and push rods for platen use within the Environmental Chamber.

• 300 kN force capacity, 150 mm (6 in) diameter, temperature range: -150 to +300°C.

• Attachment holes on the platens for connecting displacement transducers.

• Compression Push Rods for using the platens inside the environmental chamber.

11. 100kN Bend Fixture. 3- and 4-point bend testing capability. Upper and lower grips with all associated anvil, loading-pin, etc. hardware. Fixture mounting hardware and push rods for use within Environmental Chamber.

• 100 kN force capacity, temperature range: -100 to +350°C.

• Lower span adjustable from 30 to 250 mm; upper span adjustable from 25 to 90 mm.

• Maximum specimen width: 50 mm.

• 10 mm upper and lower roller pins.

• 25 mm upper and lower roller pins.

• 5 mm upper and lower roller pins.

12. Clip-On Extensometers for strain measurements.

• 50 mm gauge length, ±10% strain range. Static-rated, self-identifying, operating temperature range -100 to +200°C.

• 50 mm gauge length, +100%, -5% strain range. Static-rated, self-identifying, operating temperature range -100 to +200°C.

• 100 mm gauge length, +50%, -5% strain range. Static-rated, self-identifying, operating temperature range -100 to +200°C.

INSTALLATION:

1. On-Site Installation Services, Training, and System Warrantee.

• System Installation, Integration, and Calibration. By factory/field trained service engineers.

i. Make all physical and electrical connections, except for electrical power and/or water connections.

ii. Mount, install and test all peripheral fixtures and transducers, environmental chambers, and any major accessories that are supplied with the system.

iii. Check/verify correct operation of the system and all electrical components and mechanical assemblies and transducers (where fitted).

iv. Configure controller and test for correct operation including all adjustments and tuning.

v. Integrate controller including mountings and loading of software.

vi. Calibrate crosshead speed, displacement, load-cells, video strain, and clip-on extensometers.

SYSTEM AND SOFTWARE TRAINING

• System Onsite Training. To include:

i. System setup.

ii. General safety and testing safety precautions.

iii. General instruction on hardware elements of the system.

iv. Review of the basic operation manuals and other documentation.

• System Onsite Software Training. To include:

i. Introduction to software: fundamentals and test method development.

ii. Software operation and usage instruction.

iii. Set-up of specimen parameters, test control parameter, report templates, results calculations setup for applications.

iv. Development of five test methods.

v. Overview of test method results and report.

vi. Review of application needs. Detailed testing of customer supplied specimens to validate/verify customer test methods and applications.

• Onsite Software Instruction for Advanced Features. To include: advanced training directly related to application and the utilization of applicable software and hardware features and modules:

i. Video Extensometer System and DIC strain measurements.

ii. Load-train alignment system.

iii. Environmental Chamber.

iv. Integrated electrical instrumentation.

v. Hydraulic and other test fixtures.

WARRANTY & SITE PREP:

• System Warranty Services.

i. Service and support agreement for system while under warranty during the first year of system ownership: parts, labor and travel for repair/replacement for covered items.

ii. Telephone support during normal business hours.

iii. Remote Tech Support to monitor, diagnose, and address problems and/or system upgrades.

• Site Prep Requirements and Details.